CSP 900rmm 2 - I1r34p

Manual: CSP-900RMM-2, Rotorcraft Maintenance Manual
Models: MD900 Helicopters

Issue: Reissue No. 1:24 December 1997
Revision 34: 22 October 2010
FILING INSTRUCTIONS:
1. Before you put this revision in the manual, make sure the manual contains all the revisions
from before. Look at the last revision List of Effective Pages.
Do not put this revision in the manual, if the manual does not contain all the
CAUTION revisions from before.
2. To include this revision in the manual, remove old pages and put in new pages as shown below.
3. This revision includes all the Temporary Revisions since last revision. It is permitted to put this
revision in the manual if Temporary Revisions were not put in.
Remove Pages Insert Pages Chapter 12

Cover/Title i and ii . . . . . . . . . . . . . . . . . i and ii
Cover/Title . . . . . . . . . . . . . Cover/Title 120000
None . . . . . . . . . . . . . . . . . . 1 thru 4
Record of Temporary Revisions
201 thru 224 . . . . . . . . . . . . 201 thru 224
TRi and TRii . . . . . . . . . . . . TRi and TRii
Chapter 18
List of Effective Pages i thru ii . . . . . . . . . . . . . . . . . i thru ii
A thru H . . . . . . . . . . . . . . . . A thru H Chapter 21
Chapter 04 i thru x . . . . . . . . . . . . . . . . . i thru x
040000 215000
1 thru 4 . . . . . . . . . . . . . . . . 1 thru 4 101 thru 107/(108 blank) . 101 thru 108
201 thru 208 . . . . . . . . . . . . 201 thru 208 401 thru 428 . . . . . . . . . . . . 401 thru 448
Chapter 05 Chapter 25
i thru iv . . . . . . . . . . . . . . . . . i thru iv i thru x . . . . . . . . . . . . . . . . . i thru x
255500
050000
1 and 2 . . . . . . . . . . . . . . . . 1 and 2
1 thru 4 . . . . . . . . . . . . . . . . 1 thru 4 101 and 102 . . . . . . . . . . . . 101 and 102
051000 601 thru 604 . . . . . . . . . . . . 601 thru 606
201 and 202 . . . . . . . . . . . . 201 and 202 Chapter 26
052000 i thru iv . . . . . . . . . . . . . . . . . i thru iv
1 thru 4 . . . . . . . . . . . . . . . . 1 thru 4 261030
052010 None . . . . . . . . . . . . . . . . . . Section Cover
201 thru 212 . . . . . . . . . . . . 201 thru 212 None . . . . . . . . . . . . . . . . . . 201 thru 204
Chapter 28
052020
i thru viii . . . . . . . . . . . . . . . . i thru viii
Section Cover . . . . . . . . . . Section Cover
280000
201 thru 218 . . . . . . . . . . . . 201 thru 220
1 and 2 . . . . . . . . . . . . . . . . 1 and 2
052050 601 thru 632 . . . . . . . . . . . . 601 thru 636
201 thru 208 . . . . . . . . . . . . 201 thru 208 801/(802 blank) . . . . . . . . . 801 and 802
211 and 212 . . . . . . . . . . . . 211 and 212 Chapter 29
215 thru 218 . . . . . . . . . . . . 215 thru 218 290000
229 and 230 . . . . . . . . . . . . 229 and 230 215 thru 218 . . . . . . . . . . . . 215 thru 218
055000 Chapter 32
201 thru 264 . . . . . . . . . . . . 201 thru 268 i thru iv . . . . . . . . . . . . . . . . . i thru iv
Transmittal
Page 1
320000 601 and 602 . . . . . . . . . . . . 601 and 602
1 and 2 . . . . . . . . . . . . . . . . 1 and 2 611 thru 618 . . . . . . . . . . . . 611 thru 618
101/(102 blank) . . . . . . . . . 101 and 102 801 thru 810 . . . . . . . . . . . . 801 thru 810
401 thru 411/(412 blank) . 401 thru 416 Chapter 63
601 thru 610 . . . . . . . . . . . . 601 thru 612 i thru x . . . . . . . . . . . . . . . . . i thru x
801 and 802 . . . . . . . . . . . . 801 and 802
631000
Chapter 53 401 thru 409/(410 blank) . 401 thru 412
i thru xii . . . . . . . . . . . . . . . . i thru xii 601 thru 608 . . . . . . . . . . . . 601 thru 610
532000 801 thru 804 . . . . . . . . . . . . 801 thru 804
201 and 202 . . . . . . . . . . . . 201 and 202
Chapter 64
534000 i and ii . . . . . . . . . . . . . . . . . i and ii
201 thru 220 . . . . . . . . . . . . 201 thru 222
643000
535500 401 thru 416 . . . . . . . . . . . . 401 thru 420
405 and 406 . . . . . . . . . . . . 405 and 406
601 and 602 . . . . . . . . . . . . 601 and 602 Chapter 67
801 thru 804 . . . . . . . . . . . . 801 thru 804 671000
Chapter 62 603 thru 606 . . . . . . . . . . . . 603 thru 606
i thru viii . . . . . . . . . . . . . . . . i thru x 623 and 624 . . . . . . . . . . . . 623 and 624
620000 672000
101/(102 blank) . . . . . . . . . 101 and 102 437 and 438 . . . . . . . . . . . . 437 and 438
621000 607 and 608 . . . . . . . . . . . . 607 and 608
401 thru 406 . . . . . . . . . . . . 401 thru 410 617 and 618 . . . . . . . . . . . . 617 and 618
601 thru 608 . . . . . . . . . . . . 601 thru 612 Chapter 71
801 and 802 . . . . . . . . . . . . 801 and 802 i thru vi . . . . . . . . . . . . . . . . . i thru vi
622000 712000
411 thru 424 . . . . . . . . . . . . 411 thru 426 None . . . . . . . . . . . . . . . . . . 801 thru 804
Transmittal
Page 2
Rotorcraft
900 Series
MD Explorerr
(MDHI Model MD900r)
Rotorcraft Maintenance Manual

(CSP900RMM2)
SERVICING AND MAINTENANCE
Cover/Title Page
MD Helicopters Inc.
4555 East McDowell Road
Mesa, Arizona 852159734
Copyright E 1999-2010 by MD Helicopters, Inc. Reissue No. 1: 24 December 1997

All rights reserved under the copyright laws.
Revision No. 34: 22 October 2010
Rotorcraft
900 Series
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 customer's 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.
MD Helicopters Inc.
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.
MD Helicopters, Inc.
Bldg 615 M/S G048
Mesa, AZ 852159734
Telephone: (800) 3108539
Technical Publications Changes: (480) 3466212; FAX: (480) 3466809
Technical Publications Order Desk: (480) 3466372, FAX: (480) 3466821
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
CSP900RMM2 MD Helicopters, Inc.
This page intentionally left blank!
Page CRii
MD Helicopters, Inc. CSP900RMM2
ROTORCRAFT MAINTENANCE MANUAL (CSP900RMM2)
RECORD OF TEMPORARY REVISIONS
Rev. Date Date Rev. Date Date

No. Inserted By Removed By No. Inserted By Removed By
03001 Removed by 08004 Removed by

Revision 20 Revision 33















Page TRi
Revision 34
RECORD OF TEMPORARY REVISIONS (CONT.)
Rev. Date Date Rev. Date Date

No. Inserted By Removed By No. Inserted By Removed By
Page TRii
Revision 34
ROTORCRAFT MAINTENANCE MANUAL (CSP900RMM2)

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 change pages are:
Original (Reissue No. 1) . . . 24 December 1997 Revision 18 . . . . . . . . . . . . . . . 23 January 2003
Revision 1 . . . . . . . . . . . . . . . . . . . 22 April 1998 Revision 19 . . . . . . . . . . . . . . . . . . 20 June 2003
Revision 2 . . . . . . . . . . . . . . . . . . . . 24 July 1998 Revision 20 . . . . . . . . . . . . . 05 September 2003
Revision 3 . . . . . . . . . . . . . . . 16 February 1999 Revision 21 . . . . . . . . . . . . . 25 November 2003
Revision 4 . . . . . . . . . . . . . . . . . . . . 16 May 1999 Revision 22 . . . . . . . . . . . . . . . . . . 10 June 2004
Revision 5 . . . . . . . . . . . . . . 30 September 1999 Revision 23 . . . . . . . . . . . . . . . . 12 October 2004
Revision 6 . . . . . . . . . . . . . . . 30 December 1999
Revision 24 . . . . . . . . . . . . . 04 November 2004
Revision 7 . . . . . . . . . . . . . . . . . . . 30 June 2000
Revision 25 . . . . . . . . . . . . . . . . . . 06 April 2005
Revision 8 . . . . . . . . . . . . . . . . . 10 August 2000
Revision 26 . . . . . . . . . . . . . . . . 31 October 2005
Revision 9 . . . . . . . . . . . . . . 10 November 2000
Revision 27 . . . . . . . . . . . . . . . . . . 25 April 2006
Revision 10 . . . . . . . . . . . . . . . . . 21 March 2001
Revision 11 . . . . . . . . . . . . . . . . . . 17 April 2001 Revision 28 . . . . . . . . . . . . . 14 September 2006
Revision 12 . . . . . . . . . . . . . . . 18 January 2002 Revision 29 . . . . . . . . . . . . . . 02 February 2007
Revision 13 . . . . . . . . . . . . . . . . . . 08 April 2002 Revision 30 . . . . . . . . . . . . . . . . . . 06 April 2007
Revision 14 . . . . . . . . . . . . . . . . . . 26 April 2002 Revision 31 . . . . . . . . . . . . . . . . . 03 March 2008
Revision 15 . . . . . . . . . . . . . . . . . . 28 June 2002 Revision 32 . . . . . . . . . . . . . . . . . . . 21 July 2008
Revision 16 . . . . . . . . . . . . . . . . 19 August 2002 Revision 33 . . . . . . . . . . . . . . 12 February 2009
Revision 17 . . . . . . . . . . . . . 27 September 2002 Revision 34 . . . . . . . . . . . . . . . . 22 October 2010
Cover/Title 201 and 202 . . . . . . . . . . . . . . . . . . . . Revision 29

Cover/Title . . . . . . . . . . . . . . . . . . . . . Revision 34 203 and 204 . . . . . . . . . . . . . . . . . . . . Revision 27
205 ............................ Revision 20
Change Request
206 ............................ Revision 21
CRi and CRii . . . . . . . . . . . . . . . . . . . NA
207 thru 210 . . . . . . . . . . . . . . . . . . . . Revision 18
Temporary Revision
Chapter 04
TRi and TRii . . . . . . . . . . . . . . . . . . . . Revision 34
i and ii . . . . . . . . . . . . . . . . . . . . . . . . . Revision 25
List of Effective Pages 040000
A thru H . . . . . . . . . . . . . . . . . . . . . . . . Revision 34 1 thru 4 . . . . . . . . . . . . . . . . . . . . . . . . Revision 34
Table of Contents 201 thru 208 . . . . . . . . . . . . . . . . . . . . Revision 34
i and ii . . . . . . . . . . . . . . . . . . . . . . . . . Revision 29 Chapter 05
iii . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 6 i thru iv . . . . . . . . . . . . . . . . . . . . . . . . . Revision 34
iv . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 19 050000
Chapter 01 1 thru 4 . . . . . . . . . . . . . . . . . . . . . . . . Revision 34
i and ii . . . . . . . . . . . . . . . . . . . . . . . . . Revision 29 051000
010000 201 and 202 . . . . . . . . . . . . . . . . . . . . Revision 34
1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 26 052000
2 thru 6 . . . . . . . . . . . . . . . . . . . . . . . . Revision 14 1 thru 3 . . . . . . . . . . . . . . . . . . . . . . . . Revision 34
7 and 8 . . . . . . . . . . . . . . . . . . . . . . . . Revision 27 4 .............................. Revision 26
Page A
LOEP Revision 34
052010 205 and 206 . . . . . . . . . . . . . . . . . . . . Revision 7

201 thru 211 . . . . . . . . . . . . . . . . . . . . Revision 34 207 and 208 . . . . . . . . . . . . . . . . . . . . Revision 32
212 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 22 082000
052020 201 and 202 . . . . . . . . . . . . . . . . . . . . Original
201 thru 220 . . . . . . . . . . . . . . . . . . . . Revision 34 Chapter 09
052050 i and ii . . . . . . . . . . . . . . . . . . . . . . . . . Revision 25
201 thru 206 . . . . . . . . . . . . . . . . . . . . Revision 34 090000
207 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 28 201 thru 203/(204 blank) . . . . . . . . . Original
208 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 34 Chapter 10
209 thru 211 . . . . . . . . . . . . . . . . . . . . Revision 28 i and ii . . . . . . . . . . . . . . . . . . . . . . . . . Revision 25
212 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 34
101000
213 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 28
201 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Original
214 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 26
202 and 203 . . . . . . . . . . . . . . . . . . . . Revision 22
215 thru 218 . . . . . . . . . . . . . . . . . . . . Revision 34
204 . . . . . . . . . . . . . . . . . . . . . . . . . . . Original
219 thru 223 . . . . . . . . . . . . . . . . . . . . Revision 28 205 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 25
224 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 26 206 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Original
225 thru 227 . . . . . . . . . . . . . . . . . . . . Revision 28
102000
228 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 26
201 thru 205/(206 blank) . . . . . . . . . Original
229 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 28
230 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 34 103000
201 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 17
055000 202 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 1
201 thru 268 . . . . . . . . . . . . . . . . . . . . Revision 34
Chapter 11
Chapter 06 i and ii . . . . . . . . . . . . . . . . . . . . . . . . . Revision 26
i and ii . . . . . . . . . . . . . . . . . . . . . . . . . Revision 27
110000
060000 201 thru 216 . . . . . . . . . . . . . . . . . . . . Revision 26
201 . . . . . . . . . . . . . . . . . . . . . . . . . . . Original
Chapter 12
202 thru 204 . . . . . . . . . . . . . . . . . . . . Revision 27
i and ii . . . . . . . . . . . . . . . . . . . . . . . . . Revision 34
205 and 206 . . . . . . . . . . . . . . . . . . . . Original
120000
207 . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 18
1 thru 4 . . . . . . . . . . . . . . . . . . . . . . . . Revision 34
208 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 13
201 thru 224 . . . . . . . . . . . . . . . . . . . . Revision 34
209 and 210 . . . . . . . . . . . . . . . . . . . . Revision 18
211 and 212 . . . . . . . . . . . . . . . . . . . . Original Chapter 18
213 and 214 . . . . . . . . . . . . . . . . . . . . Revision 29 i............................... Revision 34
215 and 216 . . . . . . . . . . . . . . . . . . . . Revision 7 ii . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 29
217 thru 219 . . . . . . . . . . . . . . . . . . . . Original 180000
220 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 27 1 and 2 . . . . . . . . . . . . . . . . . . . . . . . . Revision 26
101 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 15
Chapter 07
102 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Original
i and ii . . . . . . . . . . . . . . . . . . . . . . . . . Revision 25
201 thru 206 . . . . . . . . . . . . . . . . . . . . Revision 29
071000 207 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 32
201 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 13 208 thru 212 . . . . . . . . . . . . . . . . . . . . Revision 29
202 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 22
Chapter 21
203 and 204 . . . . . . . . . . . . . . . . . . . . Original
i thru x . . . . . . . . . . . . . . . . . . . . . . . . . Revision 34
Chapter 08 212000
i and ii . . . . . . . . . . . . . . . . . . . . . . . . . Revision 32 1 and 2 . . . . . . . . . . . . . . . . . . . . . . . . Original
081000 101 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 24
201 thru 204 . . . . . . . . . . . . . . . . . . . . Revision 32 102 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Original
Page B
Revision 34 LOEP
201 thru 208 . . . . . . . . . . . . . . . . . . . . Original 601 thru 606 . . . . . . . . . . . . . . . . . . . . Revision 34

214000 256000
1 ............................. Original 1/(2 blank) . . . . . . . . . . . . . . . . . . . . . Original
2 .............................. Revision 13 201/(202 blank) . . . . . . . . . . . . . . . . . Original
3 and 4 . . . . . . . . . . . . . . . . . . . . . . . . Original 256010
101 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 24 1 thru 3/(4 blank) . . . . . . . . . . . . . . . . Revision 17
102 thru 104 . . . . . . . . . . . . . . . . . . . . Original 201 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 32
401 thru 407 . . . . . . . . . . . . . . . . . . . . Original 202 thru 205 . . . . . . . . . . . . . . . . . . . . Revision 19
413 and 414 . . . . . . . . . . . . . . . . . . . . Original 207 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 25
415 and 416 . . . . . . . . . . . . . . . . . . . . Revision 28 208 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 19
417 thru 423 . . . . . . . . . . . . . . . . . . . . Original 301 and 302 . . . . . . . . . . . . . . . . . . . . Revision 17
424 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 28 601/(602 blank) . . . . . . . . . . . . . . . . . Revision 17
601 thru 608 . . . . . . . . . . . . . . . . . . . . Revision 28 801/(802 blank) . . . . . . . . . . . . . . . . . Revision 17
215000 257000
1 thru 6 . . . . . . . . . . . . . . . . . . . . . . . . Revision 32 1 and 2 . . . . . . . . . . . . . . . . . . . . . . . . Original
101 thru 108 . . . . . . . . . . . . . . . . . . . . Revision 34 201 thru 203/(204 blank) . . . . . . . . . Original
601 and 602 . . . . . . . . . . . . . . . . . . . . Revision 32 i thru iv . . . . . . . . . . . . . . . . . . . . . . . . . Revision 34
Chapter 25 261010
i thru x . . . . . . . . . . . . . . . . . . . . . . . . . Revision 34 1 and 2 . . . . . . . . . . . . . . . . . . . . . . . . Revision 4
251000 101 and 102 . . . . . . . . . . . . . . . . . . . . Revision 4
1 thru 3/(4 blank) . . . . . . . . . . . . . . . . . Original 201 thru 204 . . . . . . . . . . . . . . . . . . . . Revision 4
101/(102 blank) . . . . . . . . . . . . . . . . . Original 261020
401 thru 414 . . . . . . . . . . . . . . . . . . . . Original 1 .............................. Revision 4
601 thru 604 . . . . . . . . . . . . . . . . . . . . Revision 33 2 .............................. Original
252000 101 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 4
1 thru 5/(6 blank) . . . . . . . . . . . . . . . . Original 102 and 103/(104 blank) . . . . . . . . . Original
101/(102 blank) . . . . . . . . . . . . . . . . . Original 201 and 202 . . . . . . . . . . . . . . . . . . . . Revision 4
401 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Original 203 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Original
403 thru 412 . . . . . . . . . . . . . . . . . . . . Original 261030
601 thru 604 . . . . . . . . . . . . . . . . . . . . Revision 33 201 thru 204 . . . . . . . . . . . . . . . . . . . . Revision 34
255000 262010
1 thru 3/(4 blank) . . . . . . . . . . . . . . . . Original 201 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 21
101/(102 blank) . . . . . . . . . . . . . . . . . Original 202 thru 204 . . . . . . . . . . . . . . . . . . . . Revision 19
401 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Original 262020
403 and 404 . . . . . . . . . . . . . . . . . . . . Original 101 and 102 . . . . . . . . . . . . . . . . . . . . Revision 4
601/(602 blank) . . . . . . . . . . . . . . . . . Original 201 . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 4
255500 202 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 22
1 and 2 . . . . . . . . . . . . . . . . . . . . . . . . Revision 34 203 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 29
101 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 34 204 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 27
403 thru 406 . . . . . . . . . . . . . . . . . . . . Original i thru viii . . . . . . . . . . . . . . . . . . . . . . . . Revision 34
Page C
LOEP Revision 34
280000 801 thru 804 . . . . . . . . . . . . . . . . . . . . Revision 1

1 and 2 . . . . . . . . . . . . . . . . . . . . . . . . Revision 34 805 thru 808 . . . . . . . . . . . . . . . . . . . . Revision 19
3 thru 5 . . . . . . . . . . . . . . . . . . . . . . . . Revision 14 Chapter 29
6 .............................. Original i and ii . . . . . . . . . . . . . . . . . . . . . . . . . Revision 25
7 .............................. Revision 14 290000
8 .............................. Original 1 thru 6 . . . . . . . . . . . . . . . . . . . . . . . . Revision 25
101 and 102 . . . . . . . . . . . . . . . . . . . . Revision 24 101 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Original
104 and 105 . . . . . . . . . . . . . . . . . . . . Revision 24 103 and 104 . . . . . . . . . . . . . . . . . . . Original
108 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 16 203 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Original
437 and 438 . . . . . . . . . . . . . . . . . . . . Revision 24 Chapter 32
439 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Original i thru iv . . . . . . . . . . . . . . . . . . . . . . . . . Revision 34
440 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 24 320000
442 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 24 101 and 102 . . . . . . . . . . . . . . . . . . . . Revision 34
449 thru 452 . . . . . . . . . . . . . . . . . . . . Revision 1 324000
453 and 454 . . . . . . . . . . . . . . . . . . . . Revision 14 201 and 202 . . . . . . . . . . . . . . . . . . . . Original
456 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 14 i thru vi . . . . . . . . . . . . . . . . . . . . . . . . . Revision 32
457 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 1 520000
458 thru 460 . . . . . . . . . . . . . . . . . . . . Revision 27 1 .............................. 20
601 thru 636 . . . . . . . . . . . . . . . . . . . . Revision 34 2 thru 6 . . . . . . . . . . . . . . . . . . . . . . . . Original
801 and 802 . . . . . . . . . . . . . . . . . . . . Revision 34 101 and 102 . . . . . . . . . . . . . . . . . . . Revision 22
281000 401 thru 415 . . . . . . . . . . . . . . . . . . . . Revision 20
1 .............................. Revision 19 416 thru 429 . . . . . . . . . . . . . . . . . . . . Revision 32
2 .............................. Revision 1 430 thru 435 . . . . . . . . . . . . . . . . . . . . Revision 22
3 and 4 . . . . . . . . . . . . . . . . . . . . . . . . Revision 19 436 thru 438 . . . . . . . . . . . . . . . . . . . . Revision 32
401 thru 408 . . . . . . . . . . . . . . . . . . . . Revision 1 801/(802 blank) . . . . . . . . . . . . . . . . . Revision 3
601 thru 605 . . . . . . . . . . . . . . . . . . . . Revision 1 i thru xii . . . . . . . . . . . . . . . . . . . . . . . . Revision 34
606 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 20 531000
607/(608 blank) . . . . . . . . . . . . . . . . . Revision 1 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 13
Page D
Revision 34 LOEP
2 thru 5/(6 blank) . . . . . . . . . . . . . . . . Original 401 thru 404 .................... Revision 33

101 and 102 . . . . . . . . . . . . . . . . . . . . Revision 24 405 and 406 .................... Revision 34
201 thru 203 . . . . . . . . . . . . . . . . . . . . Original 601 and 602 .................... Revision 34
204 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 18 801 and 804 .................... Revision 34
206 thru 214 . . . . . . . . . . . . . . . . . . . . Revision 20 i thru x . . . . . . . . . . . . . . . . . . . . . . . . . Revision 34
532000 620000
1 .............................. Original 1 .............................. Revision 3
2 thru 6 . . . . . . . . . . . . . . . . . . . . . . . . Revision 25 2 .............................. Revision 31
7 and 8 . . . . . . . . . . . . . . . . . . . . . . . . Original 3 thru 6 . . . . . . . . . . . . . . . . . . . . . . . . Revision 3
9 thru 12 . . . . . . . . . . . . . . . . . . . . . . . Revision 25 101 and 102 . . . . . . . . . . . . . . . . . . . . Revision 34
13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Original
621000
14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 25
401 thru 410 . . . . . . . . . . . . . . . . . . . . Revision 34
15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 13
601 thru 612 . . . . . . . . . . . . . . . . . . . . Revision 34
16 thru 22 . . . . . . . . . . . . . . . . . . . . . . Original
801 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 34
205 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Original 807 and 808 . . . . . . . . . . . . . . . . . . . . Revision 10
206 thru 213 . . . . . . . . . . . . . . . . . . . . Revision 7
622000
214 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Original
401 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 31
533000 402 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 28
1 thru 28 . . . . . . . . . . . . . . . . . . . . . . . Original 403 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 31
410 and 411 . . . . . . . . . . . . . . . . . . . . Revision 21 406 and 407 . . . . . . . . . . . . . . . . . . . . Revision 29
419 and 420 . . . . . . . . . . . . . . . . . . . . Original 411 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 28
427 and 428 . . . . . . . . . . . . . . . . . . . . Original 607 thru 610 . . . . . . . . . . . . . . . . . . . . Revision 29
601 and 602 . . . . . . . . . . . . . . . . . . . . Original 611 thru 618 . . . . . . . . . . . . . . . . . . . . Revision 34
603 and 604 . . . . . . . . . . . . . . . . . . . . Revision 32 801 thru 809 . . . . . . . . . . . . . . . . . . . . Revision 34
801 thru 809/(810 blank) . . . . . . . . . Original 810 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 28
534000 623000
1 thru 6 . . . . . . . . . . . . . . . . . . . . . . . . Revision 27 401 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 7
535500 416 thru 419 . . . . . . . . . . . . . . . . . . . . Revision 28
1 thru 6 . . . . . . . . . . . . . . . . . . . . . . . . Revision 33 420 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 26
Page E
LOEP Revision 34
601 thru 603 . . . . . . . . . . . . . . . . . . . . Revision 25 403 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Original

604 ............................ Revision 12 404 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 5
605 and 606 . . . . . . . . . . . . . . . . . . . . Revision 29 405 thru 408 . . . . . . . . . . . . . . . . . . . . Original
812 ............................ Revision 19 602 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Original
801/(802 blank) . . . . . . . . . . . . . . . . . Original
Chapter 63
i thru x . . . . . . . . . . . . . . . . . . . . . . . . . Revision 34 633000
401 thru 405 . . . . . . . . . . . . . . . . . . . . Original
630000
406 thru 408 . . . . . . . . . . . . . . . . . . . . Revision 13
1 .............................. Revision 25
409/(410 blank) . . . . . . . . . . . . . . . . . Original
2 thru 4 . . . . . . . . . . . . . . . . . . . . . . . . Original
601/(602 blank) . . . . . . . . . . . . . . . . . Revision 18
5 .............................. Revision 19
801 thru 806 . . . . . . . . . . . . . . . . . . . . Revision 32
6 .............................. Revision 25
7 .............................. Original Chapter 64
8 .............................. Revision 20 i and ii . . . . . . . . . . . . . . . . . . . . . . . . . Revision 34
9/(10 blank) . . . . . . . . . . . . . . . . . . . . Original 643000
101 . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 26 1 and 2 . . . . . . . . . . . . . . . . . . . . . . . . Original
601 thru 610 . . . . . . . . . . . . . . . . . . . . Revision 32
631000
801 thru 803/(804 blank) . . . . . . . . . Original
401 thru 412 . . . . . . . . . . . . . . . . . . . . Revision 34
801 thru 803 . . . . . . . . . . . . . . . . . . . . Revision 34 i thru xviii . . . . . . . . . . . . . . . . . . . . . . . Revision 32
804 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 23 670000
632000 1 thru 4 . . . . . . . . . . . . . . . . . . . . . . . . Revision 12
401 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Original 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 27
402 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 25 6 thru 13 . . . . . . . . . . . . . . . . . . . . . . . Revision 12
403 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 33 14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 27
404 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 19 15 and 16 . . . . . . . . . . . . . . . . . . . . . . Revision 12
106 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 19
801 thru 805 . . . . . . . . . . . . . . . . . . . . Revision 25
107 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 20
806 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 33
108 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 19
807 thru 811 . . . . . . . . . . . . . . . . . . . . Revision 25
812 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 33 671000
429 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 32
632100 430 thru 437 . . . . . . . . . . . . . . . . . . . . Revision 12
632200 461 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 27
101 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Original 462 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 12
401 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Original 606 and 607 . . . . . . . . . . . . . . . . . . . . Revision 31
Page F
Revision 34 LOEP

610 and 611 . . . . . . . . . . . . . . . . . . . . Revision 32 113 and 114 . . . . . . . . . . . . . . . . . . . . Revision 1
623 and 624 . . . . . . . . . . . . . . . . . . . . Revision 34 116 and 117/(118 blank) . . . . . . . . . Revision 1
671020 403 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 14
101 thru 105/(106 blank) . . . . . . . . . Original 404 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Original
406 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Original
672000 407 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 8
401 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Original 408 thru 410 . . . . . . . . . . . . . . . . . . . . Revision 14
422 thru 424 . . . . . . . . . . . . . . . . . . . . Original 602 thru 604 . . . . . . . . . . . . . . . . . . . Revision 25
428 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 28 712000
429 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 19 1/(2 blank) . . . . . . . . . . . . . . . . . . . . . Original
430 thru 437 . . . . . . . . . . . . . . . . . . . . Revision 32 401 thru 405/(406 blank) . . . . . . . . . Original
445 thru 452 . . . . . . . . . . . . . . . . . . . . Revision 33 716000
601 thru 603 . . . . . . . . . . . . . . . . . . . . Revision 29 1 thru 4 . . . . . . . . . . . . . . . . . . . . . . . . Original
606 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 32 102 and 103/(104 blank) . . . . . . . . . Original
607 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 34 401 thru 405 . . . . . . . . . . . . . . . . . . . . Original
609 thru 611 . . . . . . . . . . . . . . . . . . . . Revision 29 409 thru 411 . . . . . . . . . . . . . . . . . . . . Original
618 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 34 601 and 602 . . . . . . . . . . . . . . . . . . . . Original
803 and 804 . . . . . . . . . . . . . . . . . . . . Revision 1 717000
805 thru 807 . . . . . . . . . . . . . . . . . . . . Revision 28 1 and 2 . . . . . . . . . . . . . . . . . . . . . . . . Revision 8
808 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 29 401 thru 404 . . . . . . . . . . . . . . . . . . . . Original
Chapter 71 601/(602 blank) . . . . . . . . . . . . . . . . . Original
i thru vi . . . . . . . . . . . . . . . . . . . . . . . . . Revision 34 Chapter 75
710000 i and ii . . . . . . . . . . . . . . . . . . . . . . . . . Revision 25
1 .............................. Revision 14 750000
2 and 3 . . . . . . . . . . . . . . . . . . . . . . . . Revision 21 1 and 2 . . . . . . . . . . . . . . . . . . . . . . . . Original
4 .............................. Revision 14 201 and 202 . . . . . . . . . . . . . . . . . . . . Original
107 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 11 i and ii . . . . . . . . . . . . . . . . . . . . . . . . . Revision 29
108 and 109 . . . . . . . . . . . . . . . . . . . . Revision 14 760000
110 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 1 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 8
Page G
LOEP Revision 34
2 thru 4 . . . . . . . . . . . . . . . . . . . . . . . . Original Chapter 78

101 and 102 . . . . . . . . . . . . . . . . . . . . Revision 23 i and ii . . . . . . . . . . . . . . . . . . . . . . . . . Revision 25
103 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Original 780000
104 thru 111 . . . . . . . . . . . . . . . . . . . . Revision 29 1 and 2 . . . . . . . . . . . . . . . . . . . . . . . . Original
112 thru 115 . . . . . . . . . . . . . . . . . . . . Original 401 thru 403/(404 blank) . . . . . . . . . Original
116 thru 118 . . . . . . . . . . . . . . . . . . . . Revision 19 601 and 602 . . . . . . . . . . . . . . . . . . . . Original
119 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 29 801/(802 blank) . . . . . . . . . . . . . . . . . Original
120 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 19
401 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Original Chapter 79
402 thru 407 . . . . . . . . . . . . . . . . . . . . Revision 28 i and ii . . . . . . . . . . . . . . . . . . . . . . . . . Revision 25
408 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 23 790000
601 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 11 1 thru 4 . . . . . . . . . . . . . . . . . . . . . . . . Original
603 and 604 . . . . . . . . . . . . . . . . . . . . Revision 19 401 thru 404 . . . . . . . . . . . . . . . . . . . . Original
Page H
Revision 34 LOEP
CSP900RMM2
Front Matter
Cover/Title . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cover/Title Page
CR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Recommended Change Request
TR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Record of Temporary Revisions
LOEP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . List of Effective Pages
Aircraft General
Chapter 01 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Introduction
Chapter 04 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Airworthiness Limitations
Chapter 05 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Continued Airworthiness Inspections
Chapter 06 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Dimensions and Areas
Chapter 07 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lifting and Jacking
Chapter 08 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Leveling/Weight and Balance
Chapter 09 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Towing
Chapter 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Parking and Mooring
Chapter 11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Placards and Markings
Chapter 12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Servicing
Chapter 18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Vibration and Noise Analysis
Airframe Systems
Chapter 21 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Environmental Control System
Chapter 25 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Equipment / Furnishings
Chapter 26 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fire Protection
Chapter 28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel System
Chapter 29 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hydraulic System
Chapter 32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Landing Gear
Structure
Chapter 52 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Doors and Windows
Chapter 53 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuselage
Chapter 62 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Main Rotor
Chapter 63 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Transmission and Drive System
Chapter 64 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AntiTorque Assembly
Chapter 67 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Flight Controls
Powerplant
Chapter 71 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Powerplant
Chapter 75 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine Bleed Air
Chapter 76 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine Controls
Chapter 78 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine Exhaust
Chapter 79 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine Oil
CSP900RMM3
Electrical
Chapter 95 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Indicators, Recording Systems, and Navigation
Chapter 96 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Electrical Power
Chapter 97 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Avionics
Chapter 98 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Wiring
Page i
Contents Revision 29
01 Introduction 25 Equipment/Furnishings
010000 Introduction 251000 Crew Compartment Interior
252000 Cabin Compartment Interior
04 Airworthiness Limitations
255000 Baggage Compartment Interior
040000 Airworthiness Limitations Trim
05 Continued Airworthiness Inspections 255500 Cargo Hook System
050000 Continued Airworthiness 256000 Emergency First Aid Kit

Inspections 256010 Rescue Hoist
051000 Continued Airworthiness 257000 Hinged Avionics Shelf
Component Overhaul
26 Fire Protection
052000 Continued Airworthiness
261010 Fire/Overheat, Bleed Air Leak
Scheduled Inspection
Detection (Heat/Defog) System
055000 Continued Airworthiness 261020 Deck and Engine Area
Unscheduled Inspection Fire/Overheat Detection System
06 Dimensions and Areas 262010 Emergency Fire Extinguisher
(Hand Held)
060000 Dimensions and Areas
262020 Fire Extinguishing System
07 Lifting and Jacking
28 Fuel System
071000 Lifting and Jacking 280000 Fuel System
08 Leveling/Weight and Balance 281000 Supplemental Fuel System
081000 Weighing and Balancing 29 Hydraulic System
082000 Leveling 290000 Hydraulic System
09 Towing 32 Landing Gear

320000 Landing Gear
091000 Towing
324000 Ground Handling Wheels
10 Parking and Mooring
52 Doors and Windows
101000 Parking and Storage
520000 Doors and Windows
102000 Mooring
53 Fuselage
103000 Return to Service
531000 Windshields and Nose Area
11 Placards and Markings 532000 Lower and Center Fuselage
110000 Placards and Markings 533000 Fuselage Upper Deck and Aft Area
534000 Tailboom
12 Servicing
535500 Empennage
120000 Servicing
62 Main Rotor
21 Environmental Control System 620000 Main Rotor System
212000 Vent System 621000 Main Rotor Blade
214000 Heat/Defog System 622000 Main Rotor Hub Assembly
215000 Air Conditioning System 623000 Swashplate and Mixer
Page ii
Revision 29 Contents
63 Transmission and Drive System 71 Powerplant

630000 Rotor Drive System 710000 Powerplant
631000 Drive Shafts/Clutches/Couplings 712000 Engine Mounts
632000 Gearboxes
716000 Air Intake
632100 Transmission Lubrication and
Cooling System 717000 Engine Drains
632200 Rotor Brake 75 Engine Bleed Air
633000 Main Rotor Static Mast
750000 Engine Bleed Air
64 AntiTorque Assembly
76 Engine Controls
643000 NOTAR AntiTorque Fan System
760000 Engine Controls
67 Flight Controls
670000 Flight Controls 78 Engine Exhaust
671000 Rotor Flight Controls 780000 Engine Exhaust
671020 Collective Control Module/Cyclic
Grip 79 Engine Oil
672000 AntiTorque Flight Controls 790000 Engine Oil
Page iii
Contents Revision 6
Page iv
Revision 19 Contents
Chapter
INTRODUCTION
TABLE OF CONTENTS
Para/Figure/Table Title Page
01-00-00 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A
Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1. Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Aircraft Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
A. 900 CONFIG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
B. 902 CONFIG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
C. Engine Conversion Modification from PW206A or PW206E to PW207E . . . . . . . 2
3. Helicopter Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
A. Major Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
4. MD Explorer Publications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
A. Rotorcraft Maintenance Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
B. Rotorcraft Flight Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
C. Standard Practices Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
D. Illustrated Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
E. Shipping Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
F. Service Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
G. Illustrations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
5. Additional Publications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
A. Engine Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
B. Automatic Flight Control System (AFCS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
C. Vendor Publications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Figure 1. Helicopter - Major Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
6. ATA Numbering System and Format . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Figure 2. ATA Numbering System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
7. Division of Subject Material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
8. Page Number Blocks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
9. Figure and Table Numbering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
10. References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
11. MDHI Publications Revisions and Reissues . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
A. Revision . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
B. Reissue . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
12. Service Bulletins and Letters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
13. Application of Warnings, Cautions and Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
A. Warning Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
B. Service and Operations Report Form 853 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Maintenance Practices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
1. Maintenance and Operational Test Instructions and Precautions . . . . . . . . . . . . . . 201
Page i
01 Contents Revision 29
TABLE OF CONTENTS (Cont.)

2. Pilot's Flight Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
3. Operational Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
4. Inspections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
5. Maintenance Information Requests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
6. Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
A. Standard Hardware Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
B. Special Hardware Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
Figure 201.Special Hardware Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
7. Warning and Caution Statements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
A. Dangerous Materials Warning Statements and Icons . . . . . . . . . . . . . . . . . . . . . . . 202
B. Dangerous Material Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
8. Directives and Related Manufacturers Publications . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
Table 201.Directives and Related Manufacturers Publications (1) . . . . . . . . . . . 203
9. Optional Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
Table 202.Optional Equipment List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
10. Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
11. IIDS Troubleshooting Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
Table 203.RMM Troubleshooting IIDS Abbreviations . . . . . . . . . . . . . . . . . . . . . . 207
Page ii
Revision 29 01 Contents
Section
010000
Introduction
INTRODUCTION
DESCRIPTION AND OPERATION
1. Introduction A. 900 CONFIG
The MD Explorer (Model MD900) is a light The 900 CONFIG designates Model MD900
twin engine helicopter, provided by MD serial numbers 90000010 thru 90000051. The
Helicopters, Inc. (MDHI). The rotorcraft is 900 CONFIG is the MD900 as originally type
certified by the Federal Aviation Administra certificated.
tion under FAA Type Certificate Number
B. 902 CONFIG
H19NM. The helicopter is designed to carry
seven people, in addition to the pilot, or it can The 902 CONFIG designation started at
be fitted for internal payloads and/or for MD900 serial number 90000052 and subse
jettisonable external payloads quent. The 902 CONFIG incorporates changes
to the original MD900 to meet the require
2. Aircraft Configuration ments of FAR Part 27 Appendix C Category A.
The major changes for the 902 CONFIG are
The Model MD900 has two main production as follows:
configurations. The configurations are
designated as the 900 CONFIG and the 902 Fuel System -The 902 CONFIG fuel system
CONFIG These designations are used incorporates a longitudinal baffle in the fuel
throughout the publications applicable to the tank to provide separate left and right fuel
MD900 to indicate where the two configura supplies. The crossfeed system is removed and
tions are different. Where the two configura a fuel transfer system installed. Vapor
tions are identical, no configuration is speci shrouding is added to fuel feed system above
fied. the upper deck.
The Model MD900 helicopter is approved for Fuel Quantity -The 902 CONFIG fuel
Pratt and Whitney engines; two (2) PW206A, quantity has a separate low level light for the
or two (2) PW206E, or two (2) PW207E. left and right side of the fuel cell.
The 900 CONFIG can have the following Powerplant - The 902 CONFIG uses the
engine models installed; Pratt & Whitney 206E or 207E engine.
- PW206A engines, Pedal Anticipator -The 902 CONFIG has a
- PW206E engines, pedal anticipator. This signals the EEC of an
- PW207E engines. impending load demand increase caused by an
increase of the anti-torque fan pitch.
The 902 CONFIG can have the following
engine models installed; NACA Inlet -(National Advisory Committee
- PW206E engines, for Aeronautics). The 902 CONFIG has an
- PW207E engines. additional engine air inlet forward of the
existing inlet designated the NACA Inlet. The
Each engine model requires a specific NACA inlet is of the submerged duct design as
Electronic Engine Control (EEC) and Inte developed by NACA.
grated Instrument Display System (IIDS).
To determine which IIDS and EEC are Anti-Torque Fan Tip Seal -An improved
necessary for each engine model, reference profile tip seal is installed on the 902 CON
CSP-900IPL-4, Section 76-00-00. FIG.
Page 1
01-00-00 Revision 26
C. Engine Conversion Modification from 900 CONFIG - PW207E Engine conversion

PW206A or PW206E to PW207E
- For non-Category A helicopters (S/N 10-51)
MD Helicopters, Incorporated (MDHI) has 900 CONFIG with PW206A engines converted
received FAA approval of a change to the to PW207E engines, the helicopter is main
MD900 Type Design, which authorizes the tained in accordance with the PW207E engine
installation of PW207E engines into existing and 900 CONFIG procedures except for the
PW206A-engined MD900 helicopters, serial items listed below;
numbers 900-00010 through 900-00051 and
PW206E-engined MD900 helicopters, serial NACA inlet installed.
numbers 900-00052 through 900-00076,
900-00079, 900-00080. The FAA authoriza EEC Pedal anticipators (use 902 CONFIG).
tion is published as a note in the H19NM Type
Certificate Data Sheet (TCDS). Nr Beep Switch removed.
Any eligible MD900 helicopter with PW206A 900 CONFIG Fuel tank with 902 CONFIG
or PW206E Engines configuration, once Engine fuel supply lines.
converted, meets the MD900 with PW207E
Engines configuration Type Design. Fuel boost pump outlet fitting installed.
Completion of the conversion is not a helicop Fuel crossfeed system and the associated
ter model change and does not affect the fuel tank pump outlet check valves are
applicability of previously issued Airworthi removed (use 902 CONFIG).
ness Directives.
XFEED switch and XFEED circuit breaker
MDHI is the only maintenance facility are removed.
permitted to perform the conversion.
Left FUEL low tic mark on the IIDS does
Helicopters converted to the MD900 with not operate (#1 fuel quantity sensor is not
PW207E Engines configuration will use the installed).
existing MD900 Maintenance Publications in
addition to the appropriate Rotorcraft Flight Engine combustor wet fuel drain line ( and
Manual listed in Directives and Related fuel catch-can option) are not installed (use
Manufacturers Publications (Ref. Table 201). PW207E).
The maintenance, troubleshooting and PW207E Engine feed hose, engine feed hose
inspection procedures contained in the existing shrouding, and engine FMU shrouding (use
MD900 Maintenance Publications, 902 CONFIG).
CSP-900RMM-2 and CSP-900RMM-3, are
not affected by this conversion. The manuals Fuel system electrical (use 902 CONFIG).
already contain the various configuration
differences identified with 900 CONFIG or 902 902 CONFIG - PW207E Engine conversion
CONFIG for the airframe items and PW206A,
PW206E OR PW207E for engine configuration - For Category A helicopters (S/N 0052 thru
differences. The Illustrated Parts List 0076, 0079, 0080) 902 CONFIG with PW206E
CSP-900IPL-4 also reflects the differences. engines converted to PW207E engines, there is
no difference between the converted helicopter
Existing MD900 Service Letters and Technical and the production 902 CONFIG with
Bulletins are still applicable for the helicopter, PW207E engines. The converted helicopter is
as required. New Service Bulletins and ADs maintained as a 902 CONFIG with PW207E
for the MD900 are applicable, as required. engines.
Page 2
Revision 14 01-00-00
3. Helicopter Description The landing gear is a horizontal skid-type

gear and is not retractable. It consists of two
(Ref. Figure 1) skid tubes, two crosstubes, and a pair of
hydraulic dampers that connect the tips of the
The MD Explorer helicopter is a turbine
aft crosstube to the aft ends of the skids. The
powered, rotary wing aircraft made primarily
crosstubes clamp into saddles in the bottom of
of advanced composite materials. The rotor
the fuselage. The skids are bent upward at the
has five blades. The anti-torque system is a
front to minimize digging into soft ground in a
NOTAR anti-torque system. Engine output
nose-down run-on landing and to serve as a
is supplied to the rotor and anti-torque system
step for entering the cockpit. Three hard-sur
by drive shafts and a transmission. One way
faced anti-wear pads are placed on the bottom
overrunning clutches between the engines and
of each skid in line with the crosstubes for
transmission permits the rotor to freewheel for
protection during landings on abrasive
auto rotational descent.
surfaces.
The fuselage is a semimonocoque construction
Powerplant - The powerplant is a Pratt &
divided into three sections. The sections are
Whitney PW206A, PW206E, or PW207E
the crew, passenger and baggage compart
engine and the associated electrical, oil
ments. The basic fuselage structure consists of
cooling, and powerplant control and monitor
the sub-structure, mast support structure and
ing subsystems.
an A-Frame.
The Pratt & Whitney powerplant is a light
The crew compartment is assembled with
weight, free turbine, turboshaft engine. It
seats for the pilot and one passenger. The crew
incorporates a single stage centrifugal
compartment right seat is the pilot's seat. The
compressor, driven by a single stage turbine.
passenger compartment is directly aft of the
Metered fuel is sprayed into a reverse flow
crew compartment and contains provisions for
annular combustion chamber through fuel
folding passenger seats. Passenger seats can
nozzles mounted around the gas generator
be folded out of the way or completely removed
case. A high voltage ignition unit and dual
to accommodate cargo.
spark ignitors are used to start combustion.
The aft section of the fuselage is the baggage
A single channel Full Authority Digital
compartment and includes structure for tail
Electronic Control (FADEC) system ensures
boom attachment and the NOTAR fan
accurate control of the engine output speed
assembly.
during normal operations. An electrical
The tail boom assembly is a monocoque stepper motor located within the Fuel Meter
construction of carbon fiber composites. The ing Unit (FMU) works in conjunction with the
tail boom is the supporting structure for the Electronic Engine Control (EEC) to control and
diverter plate, horizontal stabilizer, direct jet monitor engine performance. A mechanical
thruster and control cables. throttle control overrides the FADEC system
to provide pilot control of the engine output
A. Major Components speed during abnormal or emergency condi
tions.
The MD Explorer consists of the following
major components. Fuel System - The fuel system consists of
fuel storage, distribution and vent sub-sys
Airframe - The airframe consists of the tems. The fuel system provides maximum
fuselage, tailboom, empennage, and landing safety by isolating and sealing the fuel
gear. The fuselage includes the rotor support sources. The fuel system is designed so that no
and landing gear structures. The fuselage, single failure can result in fuel starvation.
tailboom and empennage are a hybrid
construction consisting of metallic and PW206A/E CONFIG Lines and valves from
composite components. The composite materi the fuel cell to engine deck are shrouded and
als used are 350 F (176.67 C) cure graphite/ tied to an overboard drain line. This allows for
epoxy and fiberglass/epoxy with Nomex isolation of fuel leaks from the airframe and
honeycomb used, as required. cabin, while draining excess fuel overboard.
Page 3
PW207E CONFIG Lines and valves from the cyclic, collective, upper flight controls, anti-
fuel cell to engine deck are shrouded and tied. torque controls, and a vertical stabilizer
This allows for isolation of fuel leaks from the control system.
airframe and cabin. Excess fuel that is not
burned in the combustion chamber drains back Reference the KFC 900 AFCS Installation
into the fuel cell. Manual for flight control rigging of aircraft
equipped with the KFC 900 Autopilot.
Powertrain - The powertrain is mounted on
the transmission deck. The powertrain consists Environmental Control System - The
of the transmission, drive, lubrication, rotor environmental control system provides fresh
brake, and fire detection subsystems. The air, heated and cooled air for crew and
powertrain system transfers engine torque passenger comfort. The system also provides
loads to operate the Main Rotor, NOTAR, for windscreen defogging.
and Hydraulic Systems. The powertrain
system is driven by both engines or can be Electrical System - The electrical system is
driven by one engine. designed to provide the necessary electrical
power to operate and control the systems
during ground and air operations. The
Rotor System - The rotor system consists of
electrical system consists of the battery power,
the rotor hub, pitchcases, and rotor blades.
external power, DC power generation, DC
The rotor system is a five bladed fully-articu
power distribution, and lighting subsystems.
lated rotor hub located over the helicopters
center of gravity. It is mounted on the static
Instrument System - The instrument
support mast structure and receives mechani
system consists of Independent Instruments,
cal input from the rotor drive shaft. The rotor
such as airspeed, altimeter and magnetic
provides lift and helicopter lateral and
compass and the Integrated Instruments
longitudinal control. Lead-lag blade move
Display System (IIDS).
ments are dampened by elastomeric dampers.
Pitch of the blades is controlled through the
Avionics System - The avionics system
hydraulically boosted flight controls.
consists of autoflight, communications, and
navigation subsystems.
NOTAR Anti-Torque Control - The
anti-torque system provides yaw control and
4. MD Explorer Publications
stabilized helicopter rotor torque in the yaw
axis during hover and flight. The system Principle publications for the MD Explorer are
consists of an air inlet duct, enclosed articu the Rotorcraft Maintenance Manual (RMM),
lated fan driven by the transmission, air Rotorcraft Flight Manual (RFM), Illustrated
circulation control tailboom, two vertical Parts List (IPL), Standard Practices Manual
stabilizers and a direct jet thruster. (SPM), Component Maintenance Manual
(CMM), Shipping Manual, Service Bulletins,
Hydraulic System - The hydraulic system is Technical Bulletins, Service Letters and
a dual path system. Dual circuit servo-actua Ground Based Maintenance Computer
tors connect the collective and cyclic cockpit (GBMC) users guide.
controls to the upper flight controls. A single
circuit dual path servoactuator connects the The maintenance practices and procedures
anti-torque controls to the NOTAR fan and contained in MD-900 publications, are to be
direct jet thruster control linkages. The used for the MD-900 helicopter only. Study
hydraulic system components have sufficient the contents to get an understanding of the
strength to withstand combinations of loads arrangement and use of the manuals before
resulting from hydraulic pressure, vibration, working on the aircraft.
temperature variations and torque.
Operators and maintenance personnel must
Flight Controls and Rigging - The helicop refer to the current publications index for a
ter may be equipped with either right hand or complete listing of all maintenance informa
left hand control configurations consisting of tion available.
Page 4
A. Rotorcraft Maintenance Manual information possibly beneficial to the owner/

operator.
The rotorcraft maintenance manual (RMM)
gives system descriptions, servicing and Service Letters - contain information
maintenance procedures; periodic and special possibly beneficial to the owner/operator.
inspections, overhaul schedules, limited life
component replacement schedules, and weight G. Illustrations
and balance calculations. (Ref. Figure 1)
B. Rotorcraft Flight Manual The majority of illustrations represented in
The rotorcraft flight manual (RFM) contains MD-900 manuals, are oriented in a left hand
system operating instructions and operating trimetric view.
limits. Refer to the rotorcraft flight manual for 5. Additional Publications
helicopter starting and operation.
A. Engine Manual
C. Standard Practices Manual
The model PW206A, PW206E, and PW207E
The standard practices manual (SPM) contains gas turbine engines are made by Pratt and
typical practices pertaining to many different Whitney. Refer to the Pratt & Whitney
systems. The consumable materials and Maintenance Manual and the Illustrated Parts
special tools lists with source information are Catalog supplied with the engine for specific
also included. engine maintenance information
D. Illustrated Parts List (Ref. Table 201, Directives and Related
Manufacturers Publications).
CSP-900IPL-4, Illustrated Parts List (IPL)
supplies text and illustrations of repair parts B. Automatic Flight Control System (AFCS)
and spare items available for the helicopter. The KFC 900 AFCS is made by Bendix/King a
Use the IPL only parts procurement. division of Honeywell. Refer to the KFC 900
E. Shipping Manual AFCS and IFR Avionics Rotorcraft Mainte
nance Manual and Installation Manual for
This manual contains instruction for personnel AFCS maintenance information (Ref.
preparing the MD Explorer helicopter for Table 201, Directives and Related Manufactur
shipment by truck, aircraft, seagoing vessel or ers Publications).
rail transport.
Reference the KFC 900 AFCS Installation
F. Service Information Manual for flight control rigging of aircraft
equipped with the KFC 900 Autopilot.
Service Bulletins - provide aircraft upgrade
information considered mandatory by MDHI. C. Vendor Publications
Service Bulletins must be complied with to
ensure the continued safe operation of the Directives and Related Publications (Ref.
helicopter. Table 201) lists Vendor Publications, by titles
and/or identifying manual numbers. These
Technical Bulletins - provide aircraft documents must be used when performing
upgrade information not considered mandato servicing, maintenance, or repair of vendor
ry by MDHI. Technical Bulletins contain supplied helicopter components.
Page 5
ROTOR SYSTEM EMPENNAGE

ASSEMBLY
VERTICAL
STABILIZER
HORIZONTAL
POWERPLANT STABILIZER
(ENGINE
RIGHT HAND)
UPPER COWLING
AND FAIRINGS
POWERPLANT
POWERTRAIN (ENGINE LEFT HAND)
CABIN DOOR
TAILBOOM
ASSEMBLY
FUSELAGE STRUCTURE
ASSEMBLY NOTAR
ANTI-TORQUE
CONTROL
COCKPIT
DOOR
BAGGAGE
COMPARTMENT
DOOR
ANTI-TORQUE
FUEL SYSTEM FAN ASSEMBLY
COCKPIT
DOOR
CABIN DOOR
LANDING GEAR
FLIGHT ASSEMBLY
CONTROLS 9G01-001A
Figure 1. Helicopter Major Components
Page 6
6. ATA Numbering System and Format The uniform number system established by
ATA-100 is used. This number system
(Ref. Figure 2) supplies a procedure for dividing material into
chapter, section, subject and page. The number
The MDHI Maintenance Manual and related is composed of three elements, which have two
MDHI manuals are prepared in general numbers each. The chapter and section
compliance with Air Transport Association elements (subassembly 10, 20, 30, etc.) are
Specification for Manufacturers' Technical normally established by ATA-100. Subject/
Data, ATA-100. Unit element numbers are assigned by MDHI.
1ST ELEMENT 2ND ELEMENT 3RD ELEMENT
62 10 10
CHAPTER/SYSTEM SUBJECT/UNIT
MAIN ROTOR SYSTEM MAIN ROTOR BLADE
ASSEMBLY
SECTION/SUB-ASSEMBLY
MAIN ROTOR 9G01-002A
Figure 2. ATA Numbering System

7. Division of Subject Material If a subtopic becomes so lengthy that a
combination would require numerous pages,
This Maintenance Manual is provided in each topic is broken out into page number
multiple sections using ATA Specification 100 blocks as follows:
as a guide.
Description and Operation . . . . 1 through 99
CSP-900RMM-2 contains general mechanical
maintenance data. Fault Isolation . . . . . . . . . . . 101 through 199
CSP-900RMM-3 contains maintenance data Maintenance Practices . . . . 201 through 299
for instruments, electrical and avionics.
Servicing . . . . . . . . . . . . . . . . 301 through 399
8. Page Number Blocks
Removal/Installation . . . . . 401 through 499
Page number blocks used for each section of
the Maintenance Manual logically place the Adjustment/Test . . . . . . . . . . . 501 through 599
material in sequence, as follows: Inspection/Test . . . . . . . . . . . 601 through 699
Two procedures are used for numbering Cleaning/Painting . . . . . . . . . 701 through 799
maintenance practices page blocks:
Repairs . . . . . . . . . . . . . . . . . . 801 through 899
Maintenance Procedures have either a brief
subtopic or a combination of subtopics: Each page bears original issue or the latest
Description and Operation, Fault Isolation, revision number.
Removal/Installation, Inspection/Test, and
approved Repairs. 9. Figure and Table Numbering
If a subtopic or all subtopics are brief, they are Illustrations and tables use the same number
combined in one topic, under Maintenance ing as the page block in which they appear. For
Practices. All such topics are given page example, Figure 202 will be the second figure in
number blockage 201 - 299. the Maintenance Practices page block.
Page 7
10. References 12. Service Bulletins and Letters

When referring to a figure or a table in the Service information is to be considered part of
same section, it is identified by the figure or the manual.
table number. For example (Ref. Figure 202).
When referring to a figure or table in a 13. Application of Warnings, Cautions and
different section, it is identified by the figure Notes
or table number and the section number. For
example (Ref. Section 29-00-00, Figure 201). Throughout this manual, Warnings, Cautions
and Notes are used to emphasize instructions or
If it is necessary to do another task as part of information considered to be unusual or critical.
the task being preformed, the other task will Caution and Warning statements will always
be referred to in a step. If the other task is in precede the information or instructions to which
the same section, there will be no other they apply. A note can appear in text before or
reference to the task made. If the other task is after instructions to which it applies. The
not in the same section, a reference will be conditions that warrant use of Notes, Cautions
made to the section for the other task. For and Warnings are given by the subsequent.
example (Ref. Section 29-00-00).
Warnings call attention to use of
11. MDHI Publications Revisions and WARNING materials, processes, methods,
Reissues procedures, or limits which must be followed
precisely to avoid injury to persons.
Changes in the helicopter, equipment, mainte
nance practices, procedures and additional Cautions call attention to use of
information, update and replace maintenance CAUTION methods and procedures which
manual content. To ensure that MDHI if not strictly monitored, can cause damage
manuals continue to show current changes, or destruction of equipment.
revised information is supplied as follows.
NOTE: Notes call attention to methods which
A. Revision make the job easier.
Change to parts of the manual by the replace A. Warning Symbols
ment, addition and/or deletion of pages is done
by revision. The List of Effective Pages (LOEP) Symbols (or ICONs) are used as a method for
that accompanies each revision, identifies all displaying immediate graphic information. To
affected pages. Such pages must be removed obtain a technical descriptions of hazards
from the manual and discarded. Added or associated with the warning symbols in this
replaced pages must be put in and examined manual, refer to CSP-SPM, Chapter 1.
against the List of Effective Pages (LOEP).
B. Service and Operations Report Form 853
Text that is changed in a revision will be
identified by a black revision bar in the left or MDHI Service and Operations Report Form
right margin adjacent to the revised text. 853A can be used to report any service problems
Figures that have a major change will be found with the MD Explorer helicopter.
identified by a revision bar in the left or right
Use of this form is recommended, to allow
margin. Figures that have a minor change will
MDHI supply owners and operators better
have the change pointed to by a hand in the
service.
graphic.
B. Reissue The form also serves as a detailed record for
owners and operators. Copies of the form can
When several changes are included, the manual be procured by contacting:
is reissued. The preceding issue of the manual
then becomes obsolete and must be discarded. MD Helicopters, Inc.
Technical Publications
Changes that are made during a reissue will 4555 E. McDowell Road,
have no indication of changed information. A Bldg. M615/G048
reissue is considered a new pubblication. Mesa, Arizona 85215-9734
Page 8
INTRODUCTION
MAINTENANCE PRACTICES
1. Maintenance and Operational Test 5. Maintenance Information Requests
Instructions and Precautions
Address all questions regarding the MD
All helicopter maintenance must obey all Explorer maintenance to the MDHI Field
instructions and precautions as follows. Service Representative assigned to the
geographical area in which the helicopter is
2. Pilots Flight Manual operated. If a Field Service Representative is
not in the area, contact:
If helicopter operation is necessary during or
after maintenance tests, you must obey all MD Helicopters, Inc.
instructions and limits given in the applicable Field Service Department
Rotorcraft Flight Manual and all applicable 4555 E. McDowell Road,
Optional Equipment Supplements. (Ref. Bldg. M615/G048
Table 201, Directives and Related Publica Mesa, Arizona 85215-9734
tions)
If the part you think is unserviceable is
3. Operational Tests supplied by a different company; e.g., engine,
starter-generator, fuel cells, landing gear
After maintenance, modification, removal, damper, and etc., contact the part manufactur
installation, inspection, test, cleaning, er directly (Ref. Table 201, Directives and
painting, or repair; the affected parts, assem Related Publications).
blies, installations, or systems must be
examined and an operational test must be 6. Torque Values
done before release of the helicopter for flight.
Torque values are identified in the task, the
4. Inspections Standard Practices Manual, or the illustration.
Inspection procedures and wear tolerances, A. Standard Hardware Torque Values
will be supplied in the applicable chapter text.
You must do the inspections shown in Chapter Standard hardware torque values are not
05, Continued Airworthiness. identified in the task or illustration. An
example of a standard torque is: Torque screw
Inspections in this manual are inspections for (5). Item (5) in the illustration will not show a
cracks, corrosion, distortion, components torque value. For a detailed list of standard
installed correctly, other defects, or damage. torque values (Ref. CSP-SPM Section
20-10-00, Table 202).
Inspections of fuel and oil system hoses, tubes,
and fittings include inspection for corrosion, B. Special Hardware Torque Values
leakage, and distortion.
(Ref. Figure 201)
NOTE: If more than permitted limits are found,
contact MDHI Field Service Department for Special hardware torque values are identified
instructions. in the task or are shown in the illustration. An
example of a special torque would be: Torque
Replace components that show damage or clamp (1) 10-20 in-lb (1.13-2.26 Nwm) or
wear more than permitted, or that cause item (1) in the illustration will show the
incorrect operation or security of an assembly. special torque in a box pointing to item (1).
Page 201
Before you start a task, read the Warnings and

10 in-lb Cautions. If you are not sure of the dangers
2
1.1 Nm shown in the Warning, refer to Warning
Symbols (Ref. CSP-SPM, Chapter 01-00-00).
1
5 A. Dangerous Materials Warning Statements
and Icons
6 The warnings have a title followed by warning
icons. Refer to the Consumable Materials
Table (Ref. CSP-SPM, Section 91-00-00,
9 Table 201) for the material and related
4 warning symbols.
8 Warnings for dangerous material, warn
personnel of the dangers when they use them.
1
Speak to your local safety and health staff if
you are not sure about dangerous materials,
necessary personal protection equipment, how
to handle dangerous material, and emergency
7
procedures.
B. Dangerous Material Disposal
3
Obey Federal, State, and local regulations for
9G01-003 correct disposal of dangerous materials.
Figure 201. Special Hardware Torque Remove to a permitted dangerous material
disposal facility.
7. Warning and Caution Statements 8. Directives and Related Manufacturers

Publications
Detailed warnings and cautions are shown Directives and related manufacturers publica
only in the Standard Practices Manual tions that are part of the information for the
(CSP-SPM). In this manual, dangerous MD Explorer helicopter component mainte
material warnings will be shown with a title nance, are shown in Table 201. Maintenance
and icons. A warning/caution will be shown tasks will identify a related publication by
before each related task. (Ref. Section 01-00-00).
Page 202
Table 201. Directives and Related Manufacturers Publications (1)

Source Documentation Publication Title Publication No.
MDHI Publications
MD Helicopters, Inc. MD900 Rotorcraft Flight Manual (3)
4555 E. McDowell Road, 900 CONFIG with PW206A, CSP900RFM206A1,
Bldg. M615/G048 900 CONFIG with PW206E, CSP900RFM206E1,
Mesa, Arizona 85215-9734 900 CONFIG with PW207E, CSP900RFM207E1,
902 CONFIG with PW206E, CSP902RFM206E1,
902 CONFIG with PW207E, CSP902RFM207E1,
MDHI Rotorcraft Maintenance Manual CSP900RMM2

Servicing and Maintenance (RMM2)
MDHI Rotorcraft Maintenance Manual CSP900RMM3

Electrical Instruments Avionics
(RMM3)
MDHI Illustrated Parts List (IPL) CSP900IPL4
MDHI Standard Practices Manual CSPSPM

MDHI Shipping Manual CSP900SHPS
MDHI Ground Based Maintenance
Computer (GBMC) for;
(PW206A) CSP900RMM2S1
(PW206E) CSP900RMM2S2
(PW207E) CSP900RMM2S3
Vendor Publications
Battery
Saft Operating and Maintenance Manual 23861
phone: 2292452838, 275782
www.saftbatteries.com
Engine
Pratt & Whitney Canada Maintenance Manual 3038324
phone: 4506779411 (PW206A , PW206E, PW207E)
Pratt & Whitney Canada Illustrated Parts Catalog 3038326

(PW206A & PW206E)
Pratt & Whitney Canada Illustrated Parts Catalog (PW207E) 3049725
Rotor Brake
BF Goodrich Aerospace Component Maintenance Manual with BFG 419669
phone: 9374402130 Illustrated Parts List 632230 BFG 1331005
StarterGenerator
Goodrich Corp. (Formerly TRW, Lucas Maintenance Manual 23700

Aerospace, Power Equipment Corp.)
Jessica Starnes
phone: 7042822531
Page 203
Table 201. Directives and Related Manufacturers Publications (Cont.)(1)

Source Documentation Publication Title Publication No.
Goodrich Corp. (Formerly TRW, Lucas Component Maintenance Manual 23081070
Aerospace, Power Equipment Corp.) DC StarterGenerator, 23081 series 23081056
Jessica Starnes
phone: 7042822531
Wire Strike Protection System

Bristol Aerospace Limited Component Maintenance Manual PM965015
P.O. Box 874, 660 Berry Street
Winnipeg, Manitoba, Canada R3C 2S4
Flight Controls
Honeywell KFC 900 AFCS and IFR Avionics 006007500000
(or nearest Bendix/King Service Center) Installation Manual (2)
phone: 8002570726
9137122301
Honeywell KFC 900 AFCS and IFR Avionics 006007570000

Maintenance Manual Supplement (2)
Rescue Hoist System

Breeze Eastern Breeze Eastern Operation And TD96012
700 Liberty Avenue Maintenance Manual With Parts
Union, NJ. USA 070838198 Breakdown. Rescue Hoist System
NOTES:
(1) Publication must be kept and treated as part of the primary information file for the MD Explorer.
(2) Publication must be kept and treated as part of the information file for the MD Explorer Autopilot System.
(3) Including any associated RFM supplements that are ship specific.
Page 204
9. Optional Equipment NOTE:

Some options are mandatory options,
An optional installation may or may not be
which must be selected from mixed alter
necessary on the aircraft (Ref. Table 202
natives.
Optional Equipment List).
Contact MDHI Field Service Department
for compatibility of mixed alternatives or
manufacturers address and telephone
number.
Table 202. Optional Equipment List

Options Ref. RMM Chapter Part Number
Tow Bar 090000 HM7M(5/N121)
Bubble Canopy cover 100000 MD900000
Vent System P & W 212000 90000251125
Heat/Defog P & W 214000 90000251325
Air Conditioning System 215000 90000251125
Commercial Interior Red With Seats 252000 90000201400
Commercial Interior Blue With Seats 252000 90000201300
Commercial Interior Beige With Seats 252000 90000201200
Utility/Interior Without Utility Seats 252000 90000201400
Utility/Interior With Utility Seats 252000 90000201100
No Utility/Interior Without Utility Seats 252000 90000201050
Cargo Hook Configuration 255500 90000304000
Rescue Hoist System 256010 HS20200113
Fire Extinguisher, Right Hand Cabin Mounted 262010 900N7203000101
Fire Extinguisher, Left Hand Cabin Mounted 262010 900N7203001101
Fire Extinguisher, Right/Left Hand Cabin Mounted 262010 900N7203002101
Fire Extinguisher Configuration, Engine 262020 90000723000
Fuel Gravity Fill Port 280000 90000662000
Supplemental Fuel System 281000 900PG663000101
Hydraulics, Hand Pump 290000 90000012220
Ground Handling Wheel Set 324000 BDWBKH
Cockpit Doors, Quick Release 520000 9000G301000101
Cabin Step Configuration Left Side 532000 90000301000
Rotor Brake Installation 632200 90000403000
Dual Pilot 670000 9000011200
Single Pilot 670000 9000011100
Page 205
Table 202. Optional Equipment List (Cont.)

Options Ref. RMM Chapter Part Number
Copilot (Quick Release) Flight Controls 671000 90000011200
Engine Configuration P&W 710000 90000610000
Engine Wash 716000 900P7601001101
Inlet Particle Separator (IPS) With Heat/Defog 716000 90000621220
Inlet Particle Separator (IPS) Without Heat/Defog 716000 90000621210
Inlet Panel With Heat/Defog 716000 90000621120
Inlet Panel Without Heat/Defog 716000 90000621110
Fuel Catch Can Configuration 717000 90000660900
Ground Power Unit CSPSPM 910000 TI 1000GPU24
Exterior Paint #1 CSPSPM 910000 90000001100
Custom Paint CSPSPM 910000 90000001400
Main Instrument Panel Single Pilot 950000 90000724110
Main Instrument Panel Dual Pilot 950000 90000724120
Pitot Static, Heated Single 951000 90000722110
Aft Battery 961000 90007750002101
Universal Nose Mount CSP900S1 900F7309080101
Airborne Surveillance Avionics System CSP900S2
Baggage Compartment Track CSP900S3 900F7309100
Airframe Fuel Filter CSP900S4 900P5663200101
Aft Equipment Shelf CSP900S5 900F7302027
Wiper System Modification 531000 900N5200001
Wiper Switch Control Modification 531000 900N5200003
Generator Cooling Modification 716000 90005000001
Page 206
10. Abbreviations 11. IIDS Troubleshooting Abbreviations

For definitions of abbreviations used through (Ref. Table 203)
out this publication, refer to CSP-SPM, The following table provides a description of
Chapter 1. the Integrated Instrument Display System
(IIDS) and the associated abbreviations used
in the RMM Troubleshooting Tables.
Table 203. RMM Troubleshooting IIDS Abbreviations
Secondary Display on IIDS Abbreviation
ENGINE FIRE WARNING ANNUNCIATOR (RED) ENG FIRE WARNING
ENGINE CHIPS CAUTION ANNUNCIATOR ENG CHIPS CAUTION
ENGINE OIL HIGH TEMPERATURE WARNING ANNUNCIATOR ENG OIL HI TEMP WARNING
(RED)
ENGINE OIL HIGH TEMPERATURE CAUTION ANNUNCIATOR ENG OIL HI TEMP CAUTION
(YELLOW)
ENGINE OIL TEMPERATURE DIGITAL DISPLAY in C (WHITE) ENG OIL TEMP C DD

ENGINE OIL LOW TEMPERATURE CAUTION ANNUNCIATOR ENG OIL LO TEMP CAUTION
(YELLOW)
ENGINE OIL HIGH PRESSURE WARNING ANNUNCIATOR (RED) ENG OIL HI PRESS WARNING
ENGINE HIGH PRESSURE CAUTION ANNUNCIATOR (YELLOW) ENG HI PRESS CAUTION
ENGINE OIL PRESSURE DIGITAL DISPLAY in %PSI (WHITE) ENG OIL PRESS %PSI DD
ENGINE OIL LOW PRESSURE CAUTION ANNUNCIATOR ENG OIL LOW PRESS CAUTION
(YELLOW)
ENGINE OIL LOW PRESSURE WARNING ANNUNCIATOR (RED) ENG OIL LOW PRESS WARNING
GENERATOR HIGH LOAD CAUTION ANNUNCIATOR (YELLOW) GEN HI LOAD CAUTION
GENERATOR %LOAD DIGITAL DISPLAY (WHITE) GEN %LOAD DD
GENERATOR OUT CAUTION ANNUNCIATOR (YELLOW) GEN OUT CAUTION
NG HIGH WARNING ANNUNCIATOR (RED) NG HI WARNING
NG HIGH CAUTION ANNUNCIATOR (YELLOW) NG HI CAUTION
ENGINE GAS TURBINE RPM%, NG DIGITAL DISPLAY (WHITE) NG DD
NG LOW WARNING ANNUNCIATOR (RED) NG LOW WARNING
TRANSMISSION AREA FIRE WARNING ANNUNCIATOR (RED) XSMN FIRE WARNING
TRANSMISSION CHIPS CAUTION ANNUNCIATOR (YELLOW) XSMN CHIPS CAUTION
Page 207
Table 203. RMM Troubleshooting IIDS Abbreviations (Cont.)

TRANSMISSION HIGH OIL TEMPERATURE WARNING XSMN HI OIL TEMP WARNING
ANNUNCIATOR (RED)
TRANSMISSION HIGH OIL TEMPERATURE CAUTION XSMN HI OIL TEMP CAUTION

ANNUNCIATOR (YELLOW)
TRANSMISSION OIL TEMPERATURE DIGITAL DISPLAY in C XSMN OIL TEMP C DD

(WHITE)
TRANSMISSION LOW OIL TEMPERATURE CAUTION XSMN LOW OIL TEMP CAUTION
ANNUNCIATOR (YELLOW)
TRANSMISSION HIGH OIL PRESSURE WARNING ANNUNCIATOR XSMN HI OIL PRESS WARNING
(RED)
TRANSMISSION HIGH OIL PRESSURE CAUTION ANNUNCIATOR XSMN HI OIL PRESS CAUTION
(YELLOW)
TRANSMISSION OIL PRESSURE DIGITAL DISPLAY in %PSI XSMN OIL PRESS %PSI DD
(WHITE)
TRANSMISSION LOW OIL PRESSURE CAUTION ANNUNCIATOR XSMN LOW OIL PRESS CAUTION
(YELLOW)
TRANSMISSION LOW OIL PRESSURE WARNING ANNUNCIATOR XSMN LOW OIL PRESS WARNING
(RED)
FUEL QUANTITY SEGMENTS (GREEN) FUEL QTY SEGMENTS

FUEL LOW CAUTION SEGMENTS (YELLOW) FUEL LOW CAUTION SEGMENTS
FUEL LOW WARNING SEGMENT (RED) FUEL LOW WARNING SEGMENT
FUEL WARNING TICK MARKS (RED) FUEL WARNING TICK MARKS (900
CONFIG)
FUEL WARNING TICK MARKS (RED) LH INDICATES LH FUEL WARNING TICK MARKS (902
WARNING AND RH INDICATES RH WARNING CONFIG)
FUEL QUANTITY DIGITAL DISPLAY in LB (WHITE) FUEL QTY LB DD

FUEL FLOW LINES FUEL FLOW LINES
CROSS FEED VALVE POSITION ANNUNCIATOR (WHITE) FUEL XFD VLV POSN (900 CONFIG)
FUEL SHUTOFF VALVE POSITION ANNUNCIATOR (YELLOW) FUEL SOV POSN
FUEL FILTER IMPENDING BYPASS CAUTION ANNUNCIATOR FUEL FLTR IMPEND BYPASS
(YELLOW) CAUTION
LOW FUEL PRESSURE CAUTION ANNUNCIATORS (YELLOW) LOW FUEL PRESS CAUTION
CAUTIONS/WARNINGS CLUSTER CAUTION/WARNING CLUSTER
Page 208

CABIN HEAT WARNING ANNUNCIATOR (RED) CAB HEAT WARNING
BATTERY HOT WARNING ANNUNCIATOR (RED) BAT HOT WARNING
BATTERY WARM CAUTION ANNUNCIATOR (YELLOW) BAT WRM CAUTION
ROTOR BRAKE CAUTION ANNUNCIATOR (YELLOW) ROTOR BRAKE CAUTION
CABIN DOOR OPEN CAUTION ANNUNCIATOR (YELLOW) CABIN DOOR OPEN CAUTION
BAGGAGE DOOR OPEN CAUTION ANNUNCIATOR (YELLOW) BAGGAGE DOOR OPEN CAUTION
HYDRAULIC SYSTEM CAUTION ANNUNCIATOR (YELLOW); 1 HYD
ASSOCIATED IIDS A/N DISPLAY DEFINES LOW PRESSURE or HYD 2
HIGH TEMPERATURE 1 HYD 2
IIDS FAULT ANNUNCIATOR (YELLOW) IIDS FAULT CAUTION
TIME OF DAY DIGITAL DISPLAY (WHITE) TOD DD
OUTSIDE AIR TEMPERATURE DIGITAL DISPLAY in C (WHITE) OAT C DD
Primary Display on IIDS Abbreviation

IIDS ALPHANUMERIC DISPLAY IIDS A/N display
LEFT ENGINE TORQUE DIGITAL DISPLAY (WHITE) L ENG TORQUE DD
RIGHT ENGINE TORQUE DIGITAL DISPLAY (WHITE) R ENG TORQUE DD
LEFT ENGINE EGT DIGITAL DISPLAY (WHITE) L ENG EGT DD
RIGHT ENGINE EGT DIGITAL DISPLAY (WHITE) R ENG EGT DD
ROTOR NR DIGITAL DISPLAY (WHITE) ROTOR NR DD
LEFT ENGINE GAS TURBINE RPM%, NP DIGITAL DISPLAY L ENG NP DD
(WHITE)
RIGHT ENGINE GAS TURBINE RPM%, NP DIGITAL DISPLAY R ENG NP DD

(WHITE)
ENGINE OUT WARNING ANNUNCIATOR ENG OUT WARNING

EEC MINOR FAULT CAUTION ANNUNCIATOR (YELLOW) EEC CAUTION
EEC MANUAL MODE CAUTION ANNUNCIATOR (YELLOW) EEC, MAN CAUTION
EEC FAILURE WARNING ANNUNCIATOR (RED) EEC, FAIL WARNING
RED BAR SEGMENTS ARE WARNING RED SEGMENT
Page 209

Primary Display on IIDS Abbreviation
SAMPLE: RED BAR SEGMENTS L ENG EGT RED SEGMENT
YELLOW BAR SEGMENTS ARE CAUTION YEL SEGMENT
GREEN BAR SEGMENTS ARE NORMAL GRN SEGMENT
WHITE IS ADVISORY INFORMATION
RED WARNING TICK MARK WARNING TICK MARK
IIDS CONTROL KEYS:

(CLR) IIDS ACKNOWLEDGE AND CLEAR DISPLAY KEY IIDS CLR KEY
(MENU) IIDS DISPLAY MENU KEY IIDS MENU KEY
( ) IIDS UP ARROW KEY IIDS UP KEY
( ) IIDS DOWN ARROW KEY IIDS DWN KEY
(ENT) IIDS ENTER MENU KEY IIDS ENT KEY
(REC) IIDS RECORD KEY IIDS REC KEY
(DISP) IIDS DISPLAY MODE KEY IIDS DISP KEY
IIDS AlphaNumeric Display Abbreviations

EXHAUST GAS TEMPERATURE EGT
GAS GENERATOR SPEED NG
POWER TURBINE SPEED NP
ENGINE OIL PRESSURE EOP
ENGINE OIL TEMPERATURE EOT
MAXIMUM ENGINE TORQUE LOCAL Q
ROTOR SPEED NR
TRANSMISSION OIL PRESSURE XOP
TRANSMISSION OIL TEMPERATURE XOT
HYDRAULIC OIL PRESSURE HOP
Page 210
ROTORCRAFT MAINTENANCE MANUAL
Chapter
AIRWORTHINESS
LIMITATIONS
TABLE OF CONTENTS
04-00-00 Airworthiness Limitations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A

1. Approval of Airworthiness Limitations Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
2. Mandatory Replacement Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
3. Airworthiness Limitations Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
Page i

Page ii
Section
040000
Airworthiness
Limitations
AIRWORTHINESS LIMITATIONS
1. Approval of Airworthiness Limitations specify maintenance required under 43.16
and [91.403] of the Federal Aviation Regula
The Airworthiness Limitations are Federal tions (FARs) unless an alternative program
Aviation Administration (FAA) approved and has been FAA approved.
REVISION DATE FAA SIGNATURE AND DATE
Original Reissue 1 18 December 1997
Revision 1 22 April 1998
Revision 2 24 July 1998
Revision 4 7 May 1999
Revision 6 23 December 1999
Revision 7 22 June 2000
TR 00002 14 July 2000
Section 04-00-00 Not Affected This Revision.

Revision 8 10 August 2000 TR 00-002 Previously Signed.
TR 00003 13 October 2000

Revision 9 10 November 2000 TR 00-003 Previously Signed.

Revision 10 21 March 2001 TR 00-003 Previously Signed.
TR 01004 30 November 2001

Revision 12 18 January 2002 TR 01-004 Previously Signed.
Page 1
FAA Approved 04-00-00 Revision 34
TR 02001 03 March 2002

Revision 13 08 April 2002 TR 02-001 Previously Signed.
Revision 14 26 April 2002 Section 04-00-00 Not Affected This Revision.
Revision 15 28 June 2002 Section 04-00-00 Not Affected This Revision.
Revision 16 19 August 2002 Section 04-00-00 Not Affected This Revision.
Revision 17 27 September 2002 Section 04-00-00 Not Affected This Revision.
Revision 18 23 January 2003
Revision 19 20 June 2003 Section 04-00-00 Not Affected This Revision.
TR 03001 30 July 2003
Revision 20 5 September 2003
Revision 21 05 December 2003 Section 04-00-00 Not Affected This Revision.
TR 04001 09 February 2004

Revision 22 10 June 2004 TR 04-001 Previously Signed.
TR 04002 09 July 2004
Page 2
Revision 34 04-00-00 FAA Approved
TR 04004 03 November 2004

Revision 24 04 November 2004 TR 04-004 Previously Signed.
TR 05001 23 January 2006

Revision 27 25 April 2006 TR 05-001 Previously Signed.
TR06003 26 June 2006

TR 06-003 Previously Signed.
Revision 29 02 February 2007 Section 04-00-00 Not Affected This Revision.
TR07001 29 August 2007
Revision 31 27 February 2008
TR08002 14 March 2008
TR08003 02 June 2008

Revision 32 21 July 2008
TR 08-003 Previously Signed.
TR08006 14 November 2008
Page 3
Revision 33 10 February 2009
TR09001 05 May 2009
TR09002,
Chapter 040000
27 January 2010
(Published in
TR09006)
TR10005 13 May 2010
TR10007 16 August 2010
Revision 34 30 September 2010 Section 04-00-00 Not Affected This Revision.

TR09-001, TR09-002, TR10-005, and TR10-007 Previously Signed.
Page 4
AIRWORTHINESS LIMITATIONS
1. General serial number and current helicopter hours
must be recorded in the Log Book for the
The Airworthiness Limitations Schedule helicopter. The remaining number of useful life
specifies the mandatory replacement times for hours for the component with the life limit
life-limited components on the MDHI Model denotes the subsequent time at which the item
900 helicopters. must be removed from the helicopter.
At the listed life-limit hours, components or If a component with a life limit is part of an
assemblies must be removed from the helicop assembly, the assembly must be removed from
ter and permanently retired from service. the helicopter when the remaining number of
useful life hours for the component with the
At the listed inspection interval, the compo
life limit expires. The assembly may be
nents or assemblies must be inspected in
overhauled and restored to maximum number
accordance with the Rotorcraft Maintenance
of hours of useful life by installing new life
Manual (RMM) or applicable manufacturers'
limited components plus all other parts
maintenance manual.
specified in the overhaul instructions (refer to
2. Mandatory Replacement Time Component Maintenance Manual (CMM).)
The mandatory replacement time or life limit Components with a life-limit removed at
of a component of the helicopter is the as retirement are to be destroyed or conspicuous
signed maximum number of allowable ly marked to prevent inadvertent return to
operating hours. Certain assemblies and service.
components on the helicopter have a hourly 3. Airworthiness Limitations Schedule
life limit established by MDHI and approved
by FAA. The number of hours assigned to The schedule contained on the following pages
different components varies according to tabulates the mandatory replacement require
engineering fatigue tests, part experience, etc. ments.
For example, a component with an assigned
life of 1000 hours, may accumulate 1000 hours The first column of the schedule denotes to
of operation in service. Upon completion of the which model of helicopter the mandatory
1000 hours of operation, useful life of the replacement is applicable.
component is ended. The components listed in The second column contains the component
this section must be removed from the description.
helicopter at the number of hours indicated.
The third column denotes the associated
When a component with a life limit or an component part number.
assembly that incorporates a component with
a life limit is installed on a new or used The fourth column denotes the applicable life
helicopter, the nomenclature, part number, limit of the component.
Page 201
Table 1. AIRWORTHINESS LIMITATIONS SCHEDULE

Life Limit
Model Component Part Number (1)(3)
Hours
Landing Gear
900 Damper Assembly, Landing Gear 900F3361040103 2,250
900F3361040105 900
900F3361040107 5,000 (12)
Airframe
900 Main Fuselage Assembly 900F1305600105 On Condition (14)
900F1305600107 On Condition (14)
900F1305600109 On Condition (14)
900F1305600111 On Condition (14)
900F1305600113 On Condition (14)
900F1305600115 On Condition (14)
900F1305600117 On Condition (14)
900F1305600119 On Condition (14)
900F1305600121 On Condition (14)
900F1305600123 On Condition (14)
900 Tailboom Assembly 900F2318021103 On Condition (14)
900F5318022107 On Condition (14)
900 Spring Damping, Elastomeric 900F3318201103 2,000 (9)
900 Bellcrank Empennage 900F2341712101 2,700
900FP341712103 2,700
900 Cartridge, Fire Extinguisher, Primary 900P3690001101 10 Years (13)
900 Cartridge, Fire Extinguisher, Secondary 900P3690002101 10 Years (13)
Main Rotor
900 Blade, Main Rotor, Assembly 900R1150001107 600
900R1150001109 600
900R1150001111 11,460
900R1150001113 11,460
900R1150001115 11,460
900R1150002 11,460 (17)
900 Blade, Main Rotor, Assembly 900R1150003 11,460 (17)
Page 202
Table 1. AIRWORTHINESS LIMITATIONS SCHEDULE (Cont.)

Life Limit
Hours
Main Rotor (Cont.)
900 Blade Retention Bolt 900R3100001101 9,500
900R3100001103 10,750
900R3100001105 10,750
900 Flexbeam Assembly 900R1103002101 (18) On Condition (5)
900R1103003101 (18) On Condition (5)
900R1103004101 (18) On Condition (5)
900R1103005101 (18) 10,000 (5)
900R1103000105 On Condition (5)
900R1103000107 On Condition (5)
900R1103000109 On Condition (5)
900R1103000111 On Condition (5)
900 Centering Bearing Assembly, Main Rotor 900R3101001105 On Condition (15)
900R3101001107 On Condition (15)
900 Damper Cap, Upper, Main Rotor Hub 900R2100005105 10,000
900R2100005107 10,000
900R2100005109 10,000
900 Damper Cap Assembly, Lower, Main Rotor Hub 900R2100006103 10,000 (7)
900 Damper, Main Rotor 900R3100002105 4,095
900 Retention Nut, Main Rotor Hub 900R2100003101 10,000
900 Hub Assembly
Page 203

Life Limit
Hours
Main Rotor (Cont.)
Liner, Main Rotor Hub 900R2101004101 20,000
Upper Hub Assembly, Main Rotor 900R2101006101 1,730 (6)
Lower Hub Assembly, Main Rotor 900R2101008103 1,730
Hub Plate, Main Rotor 900R2101018103 1,730
Hub Plate, Main Rotor 900R2101018105 10,000
900 Striker Plate, Droop Stop 900R2101012103 10,000 (20)
900 Support, Droop Stop 900R2100001101 1,580 (10)
900R2100001103 1,580 (10)
900 Swashplate Assembly Rotating 900C2010188105 7,285 (22)
900C2010188107 7,285 (22)
900 Swashplate Assembly, NonRotating 900C2010192105 1,800
900C2010192107 1,800
900C2010192109 1,800
900C2010192111 1,800
900C2010192113 1,800
900 Lateral Mixer, Bellcrank 900C2010203105 13,000
900 Link Assembly, Collective Drive 900C2010207101 3,307
900 Link Assembly, Collective Drive, Adjustable 900C2010233103 Not to be used
900C2010233105 in service
900 Drive Ring (Main Rotor Drive Link Attachment) 900R2100007101 2,890
900R2100007103 2,890
900R2100007105 2,890
Page 204

Life Limit
Hours
Main Rotor (Cont.)
900 Bearing, Plain, SelfAligning, Spherical/Slider, Main 900C3010042103 700
Rotor
900C3010042105 12,807
Transmission and Drive System
900 Drive Shaft, Main Rotor 900D2436528101 1,450
900D6400004101 1,450
900DF436026101 1,450
900DF400100101 1,450
900 Impeller, Blower 900D3448004103 6,885
900D6448004103 6,885
900 Strut Assembly, MidAft Truss LH 900F2401300101 21,532
900F2401300103 24,158
900 Deck Fitting Assembly, Aft Truss, LH 900F2401600103 19,990
900 Deck Fitting Assembly, Aft Truss, RH 900F2401600104 19,990

AntiTorque Assembly
900 Blade Assembly, Fan, NOTAR 900R2442012101 3,800
900R2442012103 3,800
900R2442012105 3,800
900 TensionTorsion Strap, NOTAR 900R3442009101 2,500 (19) (21)
900R3442009103 2,500 (19) (21)
900R6442009103 2,500 (19) (21)
500N53115 2,500 (8) (19) (21)
900 Hub, Fan, NOTAR 900R2441013105 1,825
900R2441013107 1,825
900R2441013109 5,000
900 Pitch Plate, NOTAR 900R2443000105 3,527
900 Support Assembly, Fan NOTAR 900R1441003103 10,000
900R1441004101 10,000
900 Coupling, Fan Shaft NOTAR 900R2444002101 10,000
900R2444003101 10,000
Page 205

Life Limit
Hours
Flight Controls
900 Spring Assembly Gradient, Longitudinal 900CF010039105 260
900C6010039107 800
900C3010081101 10,000
900 Spring Assembly Gradient, Lateral 900CF010040105 260
900C6010040107 800
900C3010082101 10,000
900 Trim Actuator Assembly 900C3010004107 10,000 (11)
900C3010004113 Conditional
900C3010004115 Unlimited Life
Powerplant
900 Engine (4) (4)
900 Starter/Generator (4) (4)
Page 206
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 either overhauled, or placed in controlled storage until the life is extended, or
destroyed or conspicuously marked to prevent inadvertent return to service. Parts are applicable only on
models under which a service life is listed.
(2) Hours listed are flight hours unless otherwise noted.
(3) Interim life; life extension in progress (ref. FAA lifelimit data, Rev. BC).
(4) Ref. applicable manufacturer publications for mandatory component replacement requirements.
(5) Special inspections required at 50hour and 100hour intervals. Refer to MDHI Service Bulletin
SB900001R5 or later, and to Section 052010 for inspection requirements.
(6) Special inspections required at 100hour and 1000hour intervals. Ref. Section 052010.
(7) Special inspection required every 500hours. Ref. Section 052010.
(8) 500N53115 TensionTorsion Straps previously installed on MD900 helicopters are lifelimited to 2,500
hours when installed on MD500N series helicopters.
(9) After 2,000 hours, the life of the Elastomeric Damping Spring is On Condition but requires performance
of a Special inspection every 100 hours thereafter until deterioration is sufficient to retire assembly. Ref.
Section 052010.
(10) Special inspection required every 1,000hours or 6 months, whichever comes first. Ref. Section 052010.
(11) Aircraft Equipped with Autopilots
The 900C3010004107 trim actuator assembly must be overhauled every 5000 hours.
Aircraft not Equipped with Autopilots
The trim actuator assembly is not considered flight critical.
(12) Life of damper may use 30,000 landings instead of 5,000 hours if aircraft logs landings. Operators who
have not logged landings can apply 6 landings per hour to determine life of part.
(13) Life limit is from date of manufacture stamped on the cartridge.
(14) Inspection required at 5,000 hours and at each subsequent 2,500 hours. Ref. Section 052010.
(15) Special inspection required every 50hours. Ref. Section 052010.
(16) Special inspections required at 100hour and 300hour intervals. Ref. Section 052010.
(17) Service life shown for the basic (no dash number) part numbers apply to all dash numbered versions
unless otherwise indicated.
(18) Part number 900R1103002101 is part of 900R1103001109.
Part number 900R1103003101 is part of 900R1103001111.
(19) Special inspections required at 1200hour and subsequent 300hour intervals. Ref. Section 052010.
(20) Special inspection required every 1,000 hours. Ref. Section 052010.
(21) The tensiontorsion straps have a 5 year calendar life that starts the day the package is opened (ref.
Section 643000). If the date the package was opened is unknown, the 5year calendar life is based on
the manufacturing cure date.
For straps installed before 06 March 2008 on Model MD900 helicopters serial numbers 900000008 thru
900000123, the initial calendar replacement is based on the cure date on the strap. Refer to Table 2 to
find the expiration date.
Page 207
Table 2. TENSIONTORSION STRAP EXPIRATION DATE

Manufacturers Cure Date Expiration Date
Before March 1999 September 2008
March 1999 thru February 2001 March 2009
March 2001 thru February 2005 March 2010
March 2005 thru February 2008 Cure Date Plus 5 Years
(22) Accelerated Life Limit: For all rotorcraft SNs 900000008 thru 000124 that have incorporated Service
Bulletin SB900105 and all rotorcraft SNs 900000125 thru subsequent, timeinservice is accumulated at
an accelerated rate. To calculate the accelerated timeinservice, take the actual flight hours of the
rotating swashplate and multiply by 1.07 to determine hours toward 7,285 life limit.
Example: 6,808 actual flight hours x 1.07 accelerated life factor equals 7,285 hours.
Page 208
Chapter
CONTINUED AIRWORTHINESS
INSPECTIONS
TABLE OF CONTENTS
05-00-00 Continued Airworthiness Inspections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Regulatory Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
A. Airworthiness Limitations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
B. Component Overhaul Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
C. Scheduled Inspection Program Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
D. Unscheduled Inspections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
E. Servicing and Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
F. Vendor/Supplier Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
G. MDHI-Approved Optional Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
3. Documentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
A. Records of Aircraft Inspections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
B. Additional Documentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
4. Visual Inspection Criteria . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
A. General Visual Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
B. Corrosion Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
05-10-00 Continued Airworthiness Component Overhaul . . . . . . . . . . . . . . . . . . . A
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
2. Overhaul Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
Table 201.Overhaul Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
05-20-00 Continued Airworthiness Scheduled Inspection . . . . . . . . . . . . . . . . . . A
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Scheduled Inspections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
A. Special Inspection Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
B. Content of Scheduled Inspection Programs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
C. Airframe Periodic Inspection Program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
D. Airframe Segmented Inspection Program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
E. Changing Inspection Programs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
F. Scheduled Inspection Tolerance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
G. Inspection Areas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
H. Inspection Schedule Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Figure 1.Inspection Areas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
05-20-10 Continued Airworthiness Special Inspections . . . . . . . . . . . . . . . . . . . . . A
Table 201.Special Inspection - Hourly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
Table 202.Special Inspection - Calender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
Table 203.Special Inspection - After Component Installation . . . . . . . . . . . . . . . 211
Page i

05-20-20 Airframe Periodic Inspection Program . . . . . . . . . . . . . . . . . . . . . . . . . . . . A

Airframe Periodic Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
1. Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
Figure 201.Inspection Areas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
Table 201.Airframe Periodic Inspection General . . . . . . . . . . . . . . . . . . . . . . . . . 202
Table 202.Airframe Periodic Inspection Area 1, Nose Section and Cockpit . 203
Table 203.Airframe Periodic Inspection Area 2, Cabin Compartment . . . . . . 206
Table 204.Airframe Periodic Inspection Areas 3 and 4,
Main Rotor and Upper Transmission Deck . . . . . . . . . . . . . . . . . . . . . . . 208
Table 205.Airframe Periodic Inspection Area 5, Powerplant . . . . . . . . . . . . . . 212
Table 206.Airframe Periodic Inspection Area 6, Baggage Compartment . . . 214
Table 207.Airframe Periodic Inspection Area 7, Tailboom and Empennage . 217
Table 208.Airframe Periodic Inspection Landing Gear . . . . . . . . . . . . . . . . . . . 219
Table 209.Airframe Periodic Inspection Final Inspections . . . . . . . . . . . . . . . . 220
05-20-50 Airframe Segmented Inspection Program . . . . . . . . . . . . . . . . . . . . . . . . . . A
Routine Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
Table 201.Routine Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
Inspection 1 - Nose Section and Cockpit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
Table 202.Inspection 1 - Nose Section and Cockpit (Area 1) . . . . . . . . . . . . . . . . 207
Inspection 2 - Cabin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211
Table 203.Inspection 2 - Cabin (Area 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211
Inspection 3 - Main Rotor and Upper Transmission Deck . . . . . . . . . . . . . . . . . 215
Table 204.Inspection 3 - Main Rotor and Upper Transmission Deck
(Area 3 and 4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215
Inspection 4 - Landing Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220
Table 205.Inspection 4 - Landing Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220
Inspection 5 - Powerplant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222
Table 206.Inspection 5 - Powerplant (Area 5) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222
Inspection 6 - Baggage Compartment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 226
Table 207.Inspection 6 - Baggage Compartment (Area 6) . . . . . . . . . . . . . . . . . . 226
Inspection 7 - Tail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 230
Table 208.Inspection 7 - Tail (Area 7) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 230
05-50-00 Continued Airworthiness Unscheduled Inspection . . . . . . . . . . . . . . . A
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
2. Hard Landing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
3. Sudden Stoppage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
Page ii

A. Sudden Stoppage of the Main Rotor or Rotor Drive System . . . . . . . . . . . . . . . . . . 201

B. Sudden Stoppage of the Anti-Torque Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
4. Overtorque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
5. Overspeed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
6. Lightning Strike . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
7. Engine Out/Low Rotor Functional Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
8. Unscheduled, Conditional Inspection Tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
Table 201.Hard Landing, Level I, Conditional Inspection . . . . . . . . . . . . . . . . . . 203
Table 202.Hard Landing, Level II, Conditional Inspection . . . . . . . . . . . . . . . . . 209
Table 203.Main Rotor Sudden Stoppage, Conditional Inspection . . . . . . . . . . . . 217
Table 204.Anti-Torque Fan Sudden Stoppage, Conditional Inspection . . . . . . 223
Table 205.Overtorque Up to 110% (average input),
Conditional Inspection Both Engines Operative . . . . . . . . . . . . . . . . . 227
Table 206.Overtorque Above 110% (Average Input),
Conditional Inspection Both Engines Operative . . . . . . . . . . . . . . . . . 229
Table 207.Transmission and Drive System Overtorque,
Conditional Inspection, Single Engine Operation . . . . . . . . . . . . . . . . 233
Table 208.Transmission and Drive System Overtorque (900 CONFIG),
Conditional Inspection. Both Engines Operative,
8% Maximum Engine Torque Differential . . . . . . . . . . . . . . . . . . . . . . 235
Table 209.Transmission and Drive System Overtorque (902 CONFIG),
8% Maximum Engine Torque Differential . . . . . . . . . . . . . . . . . . . . . . 239
Table 210.Transmission and Drive System Overtorque,
Greater Than 8% Engine Torque Differential . . . . . . . . . . . . . . . . . . . 247
Table 211.Main Rotor Overspeed, 109 to 110% NR, Power Off,
Conditional Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 249
Table 212.Main Rotor Overspeed, 106 to 110% NR, Power On,
Table 213.Main Rotor Overspeed, 111 to 114% NR, Power Off,
Table 214.Main Rotor Overspeed, 111 to 114% NR, Power On,
Table 215.Main Rotor Overspeed, Over 114% NR, Power Off,
Table 216.Main Rotor Overspeed, Over 114% NR, Power On,
Table 217.Main Rotor High Vibration During Startup or Shutdown
At 35 To 40% NR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 267
Page iii

Page iv
Section
050000
Continued
Airworthiness
Inspections
Continued Airworthiness Inspections

Description
1. General ter and permanently retired from service. At
the listed inspection interval, the components
This chapter contains the Manufacturer or assemblies must be inspected in accordance
Recommended Inspection Program and with the Rotorcraft Maintenance Manual
Maintenance Requirements for Continued (RMM) or applicable manufacturers' mainte
Airworthiness defined in accordance with nance manual.
Federal Aviation Administration (FAA)
Federal Aviation Regulations (FAR) Part B. Component Overhaul Schedule
91.409(f)(3). All scheduled inspections, special
inspections, component replacement and The Continued Airworthiness Component
overhaul schedules, unscheduled inspections Overhaul section (ref. Section 05-10-00) has a
and maintenance tasks are designed to schedule for the required overhaul of compo
preserve aircraft reliability and make sure the nents and/or assemblies.
continued airworthiness and safe operation of C. Scheduled Inspection Program Overview
the MD900 Series helicopter.
The owner/operator is responsible for the
New inspection requirements, and changes to selection of an inspection program and for its
existing inspection requirements, become approval by the governing aviation authority
effective on the revision date of the change. (ref. Section 05-20-00).
Unless otherwise noted, compliance of a new
or revised inspection requirement will be done The Continued Airworthiness Special Inspec
no later than the next scheduled interval of tion requirements (ref. Section 05-20-10)
the changed item, after receipt of the revision. must be complied with in addition with the
Unless otherwise noted, an inspection in inspection program selected by the owner/oper
progress at the time a new revision becomes ator. MDHI, as the manufacturer, has devel
effective, can be completed, utilizing the oped two airframe inspection programs for
inspection criteria in effect when the inspec flexibility and maximum use of the helicopter:
tion was begun.
The Airframe Periodic Inspection Program
2. Regulatory Requirements (APIP) (ref. Section 05-20-20) and
The Airframe Segmented Inspection
The Continued Airworthiness sections describe
Program (ASIP) (ref. Section 05-20-50).
inspections and other activities that can be
required by aviation regulatory agencies. You can choose one of the MDHI programs or
design your own program.
NOTE: Alternative programs are available as
stated in the operator's local aviation regu D. Unscheduled Inspections
latory authorities' operating rules. These
alternative programs are to be approved for Unscheduled or conditional inspections are
use by the operator's local aviation regula inspection activities that are required subse
tory authority. quent to unusual or other specific conditions or
circumstances (ref. Section 05-50-00):
A. Airworthiness Limitations
Hard landing,
The Airworthiness Limitations Schedule
specifies the mandatory replacement times for Sudden stoppage,
time life-limited components (ref. Section Overtorque,
04-00-00).
Overspeed,
At the listed life-limit hours, components or
assemblies must be removed from the helicop Lightning strike, and/or
Page 1
Engine out/low rotor functional check after a Life-limited components.

modification or maintenance to the electrical
system. B. Additional Documentation
Additional documentation is necessary to be
E. Servicing and Lubrication available, or inside the aircraft, during
Refer to the Special Inspection schedules (ref. operation. This documentation includes, but is
Subject 05-20-10), the Airframe Periodic not limited to:
Inspection Program (ref. Subject 05-20-20) or Airworthiness and registration certificates,
the Airframe Segmented Inspection Program
(ref. 05-20-50) for hourly and calendar Rotorcraft Flight Manual,
servicing and lubrication requirements. Also
Weight and balance information, and
refer to the applicable manuals and service
directives from the manufacturers (ref. Section Radio permits.
01-00-00, Table 201, Vendor Publications).
It is important that all necessary documenta
Instructions and information for servicing and tion be examined and revised as necessary
lubrication of the helicopter is in Section during regular inspections, maintenance, and
12-00-00. operation of the helicopter.
F. Vendor/Supplier Information 4. Visual Inspection Criteria
Do the specified component life-limit retire When an area of the helicopter is visible
ment, inspections, lubrication, and servicing during an inspection or maintenance action, do
for the engine, appliances, and products with the General Visual Inspection (ref. Part A.)
the applicable manufacturer's publications. and the Corrosion Control (ref. Part B.)
Refer to directives and related manufacturers without disassembly or removal of adjacent
publications (ref. Section 01-00-00). equipment (unless otherwise specified). It will
normally apply to those areas, surfaces, or
Do the specified inspections in the applicable items which become visible by the removal or
publication for optional equipment approved opening of access doors, panels, fairings, or
under Supplemental Type Approval/Certificate cowlings. It must include a visual examination
(STA/STC). with the necessary inspection aids of the area,
component, detail, assembly, or installation
G. MDHIApproved Optional Equipment and its adjacent environment, in addition to
For MDHI-approved optional equipment related equipment in the adjacent area.
included in this maintenance manual, do the NOTE: Ref. CSP-SPM, Section 20-90-00, for
specified inspections in this chapter. detailed nondestructive inspection methods.
For other MDHI-approved optional equipment A. General Visual Inspection
not included in this maintenance manual, do
the specified inspections in the applicable A visual inspection to find obvious unsatisfac
publication. tory conditions/discrepancies. This inspection
can require cleaning, removal of fillets,
3. Documentation fairings, access panels/doors, etc.
A. Records of Aircraft Inspections (1). Metal parts (all metal parts, bodies, or
casings of units in systems and in
Aviation regulatory agencies require pilots, electrical, instrument, and radio
mechanics, owners and operators to know and installations, ducting, tubing, rods, and
to keep records of aircraft inspections and bellcranks) do an inspection for:
repairs. This includes, but is not limited to:
(a). Cleanliness, external signs of dam
Airworthiness directives, age, leaks, overheating, discharge, or
fluid contamination.
Service notices,
(b). Obstruction of drainage or vent
Scheduled inspection records, and holes.
Page 2
(c). Correct seating and sealing of (e). Attachments, end connections, and
fairings and serviceability of fasten locking devices are correctly
ers. attached.
(d). Components, fasteners, and connec (4). Electrical components (circuit protec
tions are correctly attached. tion devices, wiring, connectors, plugs,
motors, generators, actuators, relays,
(e). Distortion, dents, scores, chafing, solenoids, and contactors) do an
pulled or missing fasteners, rivets, inspection for:
bolts, or screws.
(a). Cleanliness, obvious damage, corro
(f). Signs of cracks or wear. sion, that components and connec
tions are correctly attached.
(g). Separation of bond.
(b). If protective covers are required to be
(h). Failure of welds or spot welds.
removed, check for cleanliness,
(i). Deterioration of protective treatment scoring, pitting or burning of con
and corrosion. tacts, brushes for condition, and that
exposed contacts are correctly
(2). Composite, rubber, fabric, fiberglass, attached.
and plastic parts (coverings, ducting,
flexible hoses, flexible mountings, seals, (c). Overheating.
insulation of electrical cables, windows, (d). Fluid contamination.
etc.) do an inspection for:
NOTE: For detailed wiring inspection criteria,
(a). Cleanliness, cracks, cuts, chafing, refer to CSP-SPM, Section 20-60-00.
kinking, twisting, crushing, or
contraction (sufficient free length). (5). Wire harnesses do an inspection for:
(b). Damage, delamination, or deteriora (a). Routing, contact with structure,
tion. proper support and protection.
(c). Crazing. (b). Strain at termination points, free
movement of shock-mounted or
(d). Loss of flexibility (other than fabric hinged equipment and proper slack
covered component). for equipment installation and
maintenance.
(e). Overheating.
(6). Inside fuel cell areas do an inspec
(f). Fluid saturation.
tion for:
(3). Control system components do an
(a). Leaks, cleanliness, foreign objects,
inspection for:
cracks.
(a). Correct alignment, no binding. (b). Components for general condition
(b). Distortion, signs of bowing, scoring, and are correctly attached.
chafing, fraying, kinking, signs of (c). Plumbing, and wiring for security,
wear, flattening, cracks, or loose and general condition.
fasteners.
(7). Markings, labels, and placards do an
(c). Deterioration of protective treatment inspection for:
or corrosion.
(a). Legibility.
(d). Electrical bonding correctly posi
tioned, undamaged, and applied. (b). Correctly attached.
Page 3
B. Corrosion Control (1). Do the Visual Corrosion Guide

Preflight Check (ref. CSP-SPM,
NOTE: For detailed Corrosion Control criteria, Section 20-40-00).
refer to CSP-SPM, Section 20-40-00.
A visual inspection to find obvious unsatisfac
tory conditions/discrepancies. This inspection (2). Do the Visual Corrosion Guide
can require cleaning, removal of fillets, Periodic Inspection (ref. CSP-SPM,
fairings, access panels/doors, etc. Section 20-40-00).
Page 4
Section
051000
Continued
Airworthiness
Component
Overhaul
CONTINUED AIRWORTHINESS COMPONENT OVERHAUL

1. General The first column (Model) of the schedule
shows which model of helicopter the
This section contains the assembly and component overhaul schedule is applicable.
component overhaul requirements. The listed
assemblies or components should be removed The second column (Component/Assembly)
from the helicopter and overhauled at inter is a brief description of the assembly or
vals specified. component.
Neither the assignment of an overhaul life to The third column (Part Number) is the
an assembly or component nor failure to applicable assembly or component part
assign a life constitutes a guarantee of any number.
kind. The only guarantees are those included
in the warranty applicable to the helicopter The fourth column (Hours) is the applicable
and any assembly or component warranty that serviceable life before overhaul.
is included in the Purchase Agreement for the
helicopter or the assembly or component. The fifth column (RMM Section) is the
applicable section of the RMM that has the
2. Overhaul Schedule procedure and requirements for overhaul of
the assembly or component. In some
Table 201 tabulates the overhaul require instances in which there is no applicable
ments for components and assemblies with RMM section, reference to other documenta
finite overhaul lives. tion or a note will appear.
Table 201. Overhaul Schedule

Hours RMM
Model Component/Assembly Part Number (1)(2) Section
Hydraulic System
900 Hydraulic Pump Assembly 900H3821501103 800 (3)
900 Hydraulic Pump Assembly 900H3821501105 4,000 (3)
900 Hydraulic Unit Dual Servoactuator, Main 900C3820021105 2,500 (4)(5)
Rotor Control
Main Rotor
900 Bearing, Ball Angular Contact, Main 900C3010100101 2,000 (6)
Rotor Swashplate 900C3010100103 2,000 (6)
Flight Controls
900 Detent Module Assembly 900C3010056101 18,750 (3)
900C3010056103 18,750 (3)
Powerplant
900 Engine (3) (3) (3)
900 Starter/Generator 23081056 1,200 (3)
23081070 1,200 (3)
Transmission
900 Transmission Assembly 900D1400006101 3000 (7)
Page 201
NOTES:
(1) Limitedlife components interchanged between models or configurations must be restricted to the lowest
service life indicated for the models or configurations affected. Limitedlife 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) Refer to Section 040000 for lifelimited parts.
(3) Refer to related manufacturer publications for component overhaul requirements (ref. Section 010000).
(4) 2,500hour Time Between Overhaul is for seals used in actuator serial numbers 9 thru 11, 13 thru 19, 21,
22, 25, 26, 27, 34 thru 37, and 39.
(5) Dual servoactuators must be overhauled by Goodrich Actuation Systems. Send dual servoactuator to
Goodrich Actuation Systems, Repair Module, 13 Avenue de IEguillette, BP 7186 (F95056
CergyPontoise Cedex), F95310 SaintOuen IAumone, France.
(6) Swashplate angular contact ball bearing requires inspection and regrease at 2000 hours or 5 years, from
original Airworthiness Certificate issuance date or last regrease, whichever comes first. Bearing must be
returned to MDHI for servicing.
(7) Return transmission to MDHI.
(8) Hours listed are flight hours unless otherwise noted.
(9) Ref. Overhaul Parts List, Rev. D.
Page 202
Section
052000
Continued
Airworthiness
Scheduled
Inspection
CONTINUED AIRWORTHINESS SCHEDULED INSPECTION

1. General The Special Inspection Hourly schedule
identifies the additional inspection require
MDHI has developed these inspection require ments that must be done at the specified
ments as the Manufacture-Recommended hourly interval.
Inspection Program in compliance with
Federal Aviation Administration (FAA) The Special Inspection Calendar
Federal Aviation Regulations (FAR) Part schedule identifies the additional inspection
91.409(f)(3): requirements that must be done at the
specified calender interval.
Refer to Section 04-00-00, Airworthiness
Limitations, for scheduled mandatory B. Content of Scheduled Inspection
replacement times (life limits) of compo Programs
nents and assemblies.
The owner/operator must do the Special (APIP) and the Airframe Segmented Inspec
Hourly and Special Calendar Inspections tion Program (ASIP) meet the scope and task
(ref. Section 05-20-10) in addition to the requirements of FAA FAR Part 43.15 and Part
Airframe Periodic Inspection Program (ref. 43, Appendix D.
Section 05-20-20) or the Airframe Seg
mented Inspection Program (ref. Section C. Airframe Periodic Inspection Program
05-20-50).
Refer to Section 05-50-00, Unscheduled (APIP) must be completed within twelve (12)
Inspections, for information on inspections calendar months of the last APIP or initial
at other than scheduled frequencies. issuance date of Airworthiness Certificate for
the helicopter.
The owner/operator is responsible for the
selection of an inspection program, and if NOTE: Review and do the one-year special in
required by regulation, for its approval by the spections the Area Inspections of the APIP.
governing aviation authority.
This inspection can be used when aviation
2. Scheduled Inspections authority regulations require periodic inspec
tions (for example, an annual or 100-hour
This section contains requirements for inspection).
scheduled inspection. Compliance with the
Rotorcraft Maintenance Manual (RMM) D. Airframe Segmented Inspection Program
information is required, and the manual
consulted when using the inspection schedules An operator can use the Airframe Segmented
for specific maintenance activity or inspection Inspection Program (ASIP) as an alternative
requirements and procedure. to the Airframe Periodic Inspection Program.
If the ASIP is used, it must be used in its
A. Special Inspection Schedule entirety.
The Special Inspection schedules (ref. Section NOTE: Review and do the one-year special in
05-20-10) contain additional hourly and spections in conjunction with the Area In
calendar inspection requirements. The Special spections in the ASIP.
Inspections (Hourly and Calender) must be
complied with at the specified interval from Routine Inspection A Routine Inspection
the previous inspection or initial issuance date is to be done at one hundred (100) hour
of Airworthiness Certificate for the aircraft. intervals as part of the ASIP.
Page 1
Performance Schedule The ASIP is prerogative and responsibility of the operator

implemented on a twelve (12) month comple to increase the scope and frequency of the
tion cycle. inspection activities as necessary to make sure
of safe operation.
NOTE:
Each inspection item must conform with the
The segment schedule has been short
aviation regulatory requirements, airworthi
ened and reorganized for ease of use by
ness directives (ADs), and service bulletins
the elimination of duplicated Segment 7
(SBs). Inspection intervals identified therein
(included the repetitive portions of the
are the maximum permitted and must not be
Segment 7 inspection in Routine Inspec
exceeded.
tion) and the creation of equal intervals
for the segments thru the year (new 12 For maintenance scheduling convenience, with
Month segments, first published in June the exception of an inspection required by the
2004). local governing civil aviation authorities:
A change from the old 24-month segment Hourly inspection intervals can be extended
schedule to the new 12-month segment by ten (10) percent.
schedule requires a Segment 7 inspection.
Calender inspection intervals can be
extended fourteen (14) days for one (1) year
Segmented Inspection requirements and thirty (30) days for two (2)
Month or more year requirements.
New Old
12 Month 24 Month An inspection interval extension must be
deducted from the next inspection interval.
1 / 13 N/A N/A Example: if a 300-hour inspection require
2 / 14 1 7 ment is done at 330 hours, it is next due in
270 hours with a possible extension of 27
3 / 15 N/A 1 hours.
4 / 16 2 N/A NOTE: Over flying a specified regulatory au
thority inspection interval, or a change to
5 / 17 3 2
the requirements of this chapter, can be re
6 / 18 N/A 4 quested through the local governing civil
aviation authorities.
7 / 19 4 5
G. Inspection Areas
8 / 20 5 7
The aircraft has been divided into seven
9 / 21 N/A N/A different inspection areas (ref. Figure 1). Each
area is addressed independently by the
10 / 22 6 3 inspection program with multiple area
11 / 23 N/A N/A inspection requirements only when necessary.
12 / 24 7 6 H. Inspection Schedule Guide

The tables for each inspection program/re
quirement are divided into four columns:
E. Changing Inspection Programs
The first column is for the model of helicop
Before you start a new inspection program or ter the inspection is applicable. The 900 in
change to a different inspection program, the the first column shows the model MD900.
operator must do the requirements of an
Airframe Periodic Inspection Program and the NOTE: The MD900 is the only model listed in
1-year special inspection schedules. the Type Certificate Data Sheet (H19HM).
The 902 is a configuration difference (ref.
F. Scheduled Inspection Tolerance Section 01-00-00, Aircraft Configuration).
When unusual local conditions, such as The second column is a brief description of
environment, use, etc., dictate, it is the the inspection requirement.
Page 2
The third column refers to the applicable performance of the specified inspection.
section of the RMM for the specified
requirements and procedures for that
inspection. All completed inspection schedules must be
kept as a permanent part of the helicopter
The fourth column is for verification of the records.
9G05-002
1. NOSE SECTION AND COCKPIT 5. POWERPLANT
2. CABIN COMPARTMENT 6. BAGGAGE COMPARTMENT
3. UPPER TRANSMISSION DECK 7. TAILBOOM AND EMPENNAGE
4. MAIN ROTOR
Figure 1. Inspection Areas
Page 3
Page 4
Section
052010
Continued
Airworthiness
Special Inspections
CONTINUED AIRWORTHINESS SPECIAL INSPECTIONS

Table 201. Special Inspection Hourly
Registration No. Serial No. Helicopter Total Hours

Model Requirement RMM Section Initial
50 Hour
Main Rotor: Flexbeam Inspection (PN 900R1103001109 and 111) [Ref. Note (1)]
900 Do the Flexbeam Inspection. Examine main rotor flexbeam for 622000
cracks, delamination, and defects. It is not necessary to remove the
pitchcase or use a borescope.
Main Rotor: Centering Bearing Inspection [Ref. Note (1)]
900 Do the 50Hour Inspection for the Centering Bearing Assemblies. 622000
Examine main rotor centering bearings for cracks and defects.
Engine Exhaust: Primary Exhaust Nozzle Assembly (Stainless

Steel) Inspection (for rotorcraft with PW206A engines
installed)
900 Do the Primary Exhaust Nozzle Assembly (Stainless Steel) Special 780000
Inspection. Examine primary exhaust nozzle for cracks and
defects.
100 Hour
cracks, delamination, and defects. It is necessary to remove
cracks, delamination, and defects. It is not necessary to remove
Main Rotor:
900 Do the 100Hour Inspection of the Main Rotor Hub Assembly . 622000
900 Do the Main Rotor Blade Abrasion Strip Inspection. 621000
Powerplant:
900 Deleted. Moved to Section 052020, Airframe Periodic Inspection.
Page 201
Table 201. Special Inspection Hourly (Cont.)

100 Hour
Transmission and Drive System:
900 Do a check of the main rotor drive plate nut torque at the initial 631000
helicopter 100hour inspection. Refer to Main Rotor Drive Plate Nut
Torque Check.
900 Deleted. Moved to 1000 Hour Special Inspection.
900 Do the transmission Chip Detector Test. 632000
AntiTorque Assembly:
900 Do the AntiTorque Drive Shaft Inspection. Examine fan drive shaft 631000
for damage or defects.
900 Examine antitorque fan blades for damage and defects. Refer to 643000
Table 601. Fan Blade Damage Limits.
900 Examine counterweights on pitch horn for correct installation. Refer 643000
to AntiTorque Fan Component Inspection.
900 Examine fan hub sleeves for damage. Refer to AntiTorque Fan 643000
Component Inspection and Table 602. Fan Hub Damage Limits.
Landing Gear:
900 Examine skid tube abrasion strips for wear and correct installation. 320000
Refer to Skid Tube Assembly Inspection.
900 If ground handling wheels have been attached to Station 203 320000
forward ground handling attachment pins: and
Examine skid tube upper surface between the aft ground handling CSPSPM
wheel attach pins. Refer to Skid Tube Assembly Inspection and do 209000
a Fluorescent Penetrant Inspection.
VSCS:
900 Do the VSCS Operational Test or VSCS Check. 672000
or
Rotorcraft
Flight Manual
Page 202

100 Hour
Hydraulic System:
900 Do the Hydraulic System Operational Test (Aircraft Ground Run) or 290000
Hydraulic System Check (ref. the appropriate Rotorcraft Flight and
Manual). Rotorcraft
Flight Manual
Fuel:
900 Do the Fuel Cell Longitudinal Baffle Integrity Test (902 CONFIG). 280000
Do the Fuel Transfer System Functional Test (902 CONFIG).
300 Hour
Transmission and Drive System: 3Micron Lubrication Pump Filter Replacement
[Ref. Note (2)]
900 Remove and replace 3micron transmission lubrication pump filter 632100
assembly (ref. procedures of Lubrication Pump Filter Assembly
Removal or Installation).
Transmission and Drive System: Main Rotor Drive Shaft, Drive Plate and Static Mast
Inspection (Yearly or 300 hours whichever occurs first)
900 Do the Drive Plate Inspection and Main Rotor Drive Shaft 631000
Inspection. 633000
Remove, inspect, and regrease main rotor drive shaft and drive
plate.
Examine internal static mast in accordance with instructions of Main
Rotor Static Mast Inspection.
Main Rotor:
900 Do the Gap Check of the Blade Retention Bolts (103 and 105). 621000
900 Do the Inspection of the Upper Hub Flange. 622000
Fuel:
900 If supplemental fuel system is installed: CSPSPM
Examine the AUX FUEL XMIT circuit breaker, circuit breaker lugs
and electrical termination connections for the correct installation.
Flight Controls:
900 Do a Trim Servo PN 900C3010004107 Electronic Stop Test 671000
Verification and Replacement (Longitudinal and Lateral Trim
Actuators).
Starter/Generators:
900 Do a starter/generator bench inspection. (6)
Page 203

300 Hour
Tailboom: Tailboom External and Internal Inspection
(Yearly or 300 hours whichever occurs first)
900 Deleted. Moved to Table 202.
900 Examine the control cable attach bracket for cracks, corrosion, and 534000
condition.
AntiTorque Assembly: TensionTorsion Straps [Ref. Note (7)]
900 Do the TensionTorsion Strap Inspection. 643000
400 Hour
Main Rotor: Main Rotor Hub Upper Bearing Inspection
900 Do the Main Rotor Hub Assembly Upper Bearing Inspection. 622000
500 Hour
Main Rotor: Lower Damper Cap Assembly Inspection

900 Examine lower damper cap assemblies for condition and proper 622000
installation, in accordance with instructions in Main Rotor Hub
Assembly Inspection.
600 Hour
Environmental Control System: AirConditioning Compressor Reduction Gearbox

Servicing (Yearly or 600 hours whichever occurs first)
900 Do the AirConditioning Compressor Reduction Gearbox Draining 120000

and AirConditioning Compressor Reduction Gearbox Servicing.
Antitorque Installation:
900 Do the AntiTorque Fan Support Inspection. 643000

Examine the fan support shaft bearing.
900 Examine the fan pitch bearing, in accordance with instructions in 643000
AntiTorque Fan and Pitch Control Component Inspection Pitch
Control Inspection.
900 Do the Fan Bearing Lubrication. 120000

Regrease the fan support shaft bearing.
900 Do the Fan Bearing Lubrication. 120000

Regrease the fan pitch bearing.
Page 204

600 Hour
Transmission and Drive System: Transmission Oil Replacement
900 Do the Main Transmission Draining and Main Transmission 120000

Filling/Replenishing.
Transmission and Drive System: Transmission 75Micron Oil Filter Cleaning/Replacement

[Ref. Note (3)]
900 Clean or replace transmission 75micron oil filter, in accordance 632100

with instructions in Lubrication Pump Filter Assembly Removal and
Installation.
1000 Hour
Main Rotor: Upper Hub Inspection [Ref. Note (1)]
900 Do the Eddy Current Inspection of the Main Rotor Upper Hub 622000
Assembly.
Main Rotor: Support, Droop Stop
900 Examine Droop Stop Support, in accordance with instructions in 622000

Annual Inspections for the Main Rotor Hub Assembly.
Main Rotor: Striker Plate, Droop Stop [Ref. Note (1)]
900 Examine Droop Stop Striker, in accordance with instructions in 622000

Main Rotor Hub Assembly Inspection.
Main Rotor: Drive Ring (Yearly or 1,000 hours whichever occurs first)
900 Examine Drive Ring in accordance with instructions in Main Rotor 622000
Hub Assembly Inspection.
Transmission and Drive System:
900 Do the Acoustic Isolator Inspection. Examine outer surfaces of 632000

acoustic isolator for condition, and transmission attach bolts for
correct installation and indications of fretting.
1200 Hour
AntiTorque Assembly: TensionTorsion Straps [Ref. Note (7)]
900 Do the TensionTorsion Strap Inspection. 643001
VSCS Actuator [Ref. Note (8)]
900 Do the VSCS Actuator Regrease Procedure. 672000
Page 205

2000 Hour
Empennage: Elastomeric Damping Spring Condition [Ref. Note (5)]
900 Do the Elastomeric Damper Condition Test. 535500
900 Examine upper and lower endplates: 535500
Exterior surfaces for apparent defects and general condition
Attachment hardware for security
For improper movement (wiggle).
5000 Hour and at Each Subsequent 2500 Hours of Operation

Airframe: Fuselage and Tailboom Inspection [Ref. Note (1) and (4)]
900 Examine airframe in accordance with instructions in 532000
Airframe Continued Airworthiness Inspection.
Contact a MDHI Field Service Representative.
NOTES:
(1) Ref. Section 040000 for part number applicability.
(2) If 3micron filter has been replaced in the last 150 hours, change 3micron filter at the next 300hour
interval.
(3) The 75micron filter can be cleaned a maximum of four (4) times. Maximum filter life cannot be more
than 1200 hours or 24 months.
(4) This inspection is to maintain the continued airworthiness of the MD900 airframe after the demonstrated
life limit has been reached.
(5) After 2000 hours, the life of the elastomeric damping spring is On Condition but requires a Special
Inspection every 100 hours thereafter until deterioration is sufficient to retire assembly.
(6) Refer to the applicable manufacturer publications (ref. Section 010000).
(7) After 1200 hours, the TensionTorsion Strap Inspection is required at 300hour intervals until the life
limits of the tensiontorsion straps are reached.
(8) If not done before, do the VSCS Actuator Regrease Procedure at the next scheduled inspection. But no
later than the next 100 hours.
Page 206
Table 202. Special Inspection Calender

DAILY
Rotorcraft
900 During operation in a corrosive environment, do a rinse of the CSPSPM
rotorcraft (ref. the instructions in Rotorcraft Rinse). 202000
14 DAY
Rotorcraft
900 During operation in a corrosive environment, do a wash of the CSPSPM
rotorcraft (ref. the instructions in Rotorcraft Wash). 202000
6 MONTH
Main Rotor: Support, Droop Stop
900 Examine the droop stop support (ref. the instructions in Main Rotor 622000
Hub Assembly Inspection).
1 YEAR (Do a the 1 YEAR requirements in conjunction with the Area Inspections in the ASIP)
Environmental Control System: AirConditioning Compressor Reduction Gearbox
Servicing (Yearly or 600 hours whichever occurs first)
900 Do the Air Conditioning Compressor Reduction Gearbox Draining 120000

and Air Conditioning Compressor Reduction Gearbox Servicing.
Environmental Control System: Optional Heat/Defog System Inspection

900 Do the Heat / Defog System Bleed Air Engine/Firewall Inspection. 214000
Examine bleed air engine/firewall components for general condition
and security.
900 Do the Heat / Defog Tube Assemblies Inspection, and Under Floor 214000
Tube Assemblies Inspection. Examine bleed air tube installation for
evidence of bleed air line failure, general condition of insulation, and
security of supports and hardware.
Fire Protection: Hydrostatic Testing of Fire Extinguisher Containers

900 Make sure compliance with hydrostatic testing of fire extinguisher 262020
containers.
Fire Protection: Service Life Limit of Discharge Cartridges

900 Make sure compliance with service life requirements of fire 262020
extinguishing container primary and alternate cartridges.
Fuel System: Functional Check of Low Fuel Light

900 900 CONFIG Do the Low Fuel Light Functional Test. 280000
902 CONFIG Do the Fuel Transfer System Functional Test.
Page 207
Table 202. Special Inspection Calender (Cont.)

Fuel System: Fuel Vent System Inspection
900 Do the Fuel Vent System Inspection. Examine fuel vent system 280000
components and interconnecting lines for condition and proper
installation.
Fuel System: Vapor Shroud System Inspection
900 Do the Vapor Shroud Box, Cover Assembly and Vapor Shroud Hose 280000
Inspection. Examine vapor shroud boxes, cover assemblies, and
interconnecting hoses for condition and proper installation.
Landing Gear: Landing Gear Cross Tube Inspection
900 Do the Forward Crosstube Inspection and Aft Crosstube 320000
Inspection. Make sure that forward and aft cross tube spread is
within allowable maximum limits.
Fuselage: Cabin Door Latch Mechanism Rigging Verification
900 Do the Cabin Door Latch Mechanism Rigging Verification 520000
Fuselage: Fuselage Internal Structure Inspection
900 Examine cockpit floor substructure and installation for distortion, 532000
corrosion, apparent defects, and security of attachment hardware:
Examine plough beams and attachment components.
Examine FS 106.00 bulkhead assembly and attachment
components.
Examine FS 130.00 bulkhead assembly and attachment
components.
Examine crew seat fittings and attachment components.
900 Examine FS 155.50 frame assembly and installation for distortion, 532000
corrosion, apparent defects, and security of attachment hardware.
900 Examine AFrame assembly and installation for distortion, corrosion, 533000
apparent defects, and security of attachment hardware:
Examine vertical leg and center beam components.
Examine forward mast fitting assemblies.
900 Examine outboard side of keel beam assemblies: 532000
For cracks, delamination, and apparent defects. and
CSPSPM
Attached ribs and components for correct installation and 209000
attachment of hardware.
Page 208

Pitot Static System: Pitot Static Moisture Drain
900 Do the Static System Moisture Drain Procedure. 951000

Drain pitot and static drains.
Fuselage: Fuselage Internal Structure Inspection (Cont.)
900 Examine keel beam to tub shell joints: 532000

Early Config Do a coin tap test on keel beam bottom cap to tub and
bond from underside of aircraft. CSPSPM
209000
Current Config Examine attaching rivets for loose or working
rivets.
900 Examine roof structure and installation for distortion, corrosion, 533000
apparent defects, and security of attachment hardware:
Examine forward, mid, and aft deck structure longerons.
intercostals, channels and frames.
Examine flight controls support components.
Examine roof beam installation components.
900 Examine FS 230.50 bulkhead assembly and installation for distortion, 533000
corrosion, apparent defects, and security of attachment hardware.
Tailboom: Tailboom External and Internal Inspection
900 Do the Tailboom Inspection. 534000
Transmission and Drive System: Main Rotor Drive Shaft and Drive Plate Inspection
900 Remove, examine, and regrease main rotor drive shaft and drive 631000
plate.
Do the Main Rotor Drive Shaft Inspection.
Do the Main Rotor Drive Shaft Removal and Installation.
Do the Drive Plate Inspection.
Do the Main Rotor Drive Plate Removal and Installation.
Transmission and Drive System: Transmission Oil Replacement

900 Do the Main Transmission Draining and Main Transmission 120000

Filling/Replenishing. Drain and service transmission.
Transmission and Drive System: 75Micron Lubrication Pump Filter Replacement

[REF. NOTE (1)]
900 Clean or replace transmission 75micron oil filter (ref. the instructions 632100
in Lubrication Pump Filter Assembly Removal and Installation).
Page 209

Main Rotor: Drive Ring (Yearly or 1,000 hours whichever occurs first)
900 Examine drive ring (ref. the instructions in Main Rotor Hub Assembly 622000
Inspection).
Main Rotor: Lower Damper Cap Assembly Inspection

900 Examine lower damper cap assemblies for condition and correct 622000
installation (ref. the instructions in Main Rotor Hub Assembly
Inspection).
Flight Controls: Rotor Flight Controls
900 Do the Rotor Flight Controls Rigging Check. 671000
Fire Protection: Container Weight Verification
900 Do the Weight Verification Of Fire Bottle. 262020
Remove and weigh fire extinguisher containers.
2 YEAR
Fire Protection System: Bridgewire Resistance Test
900 Do the Discharge Cartridge Bridgewire Resistances Test. 262020
Main Rotor: Main Rotor Hub Bearing Grease Replacement
900 Replace main rotor hub upper and lower bearing grease (ref. the 622000
instructions in Upper Seal, Upper Hub Assembly and Lower Seal,
Upper Hub Assembly).
Main Rotor: Main Rotor Hub Lower Bearing Inspection

900 Do the Main Rotor Hub Assembly Lower Bearing Inspection. 622000
Examine main rotor hub lower bearing.
900 Do the Swashplate Assembly Upper Bearing Inspection. 623000

Examine the main rotor swashplate bearing for evidence of grease
leakage and/or corrosion.
5 YEAR
Fire Protection: Hydrostatic Testing of Fire Extinguisher Containers
900 Do a hydrostatic testing of fire extinguisher containers. 262020
NOTES:
(1) The 75micron filter can be cleaned a maximum of four (4) times. Maximum filter life cannot be more than
1200 hours or 24 months.
Page 210
Table 203. Special Inspection After Component Installation

Equipment / Furnishings
Cargo Hook Installation: Cargo Hook System Inspections and Tests
900 Do these inspections and tests when a cargo hook is installed: 255500
After installation of the cargo hook system, do a Cargo Hook
System Functional Test.
Before each use, do these inspections and test:
General Inspection,
Cargo Hook Inspection,
Cable (Wire Rope) Inspection, and a
Cargo Hook System Operational Test.
Main Rotor
Main Rotor: Blade Retention Bolt Torque Check
900 After a main rotor blade and blade retention bolt installation, do a 621000
Blade Retention Bolt Torque Check at these intervals:
After first flight.
Every 4 to 10 hours of flight operation after the firstflight check
until:
(101) The bolt torque is not less than 800 inlb (90.4 Nm).
(103) The closing force has not changed more than 10 percent
of the recorded final installation force and is not less than 65 lbf
(29.5 kgf).
(105) The closing torque has not changed more than 10
percent of the recorded final installation torque and is not less
than 350 inlb (39.5 Nm).
Main Rotor: Main Rotor Drive Plate Nut Torque Check
900 Do a Main Rotor Drive Plate Nut Torque Check at these intervals: 631000
After first flight.
Every 4 to 10 hours of flight operation until there is no loss of
torque.
During the next 100hour inspection after an installation.
Page 211
Page 212
Section
052020
Airframe Periodic
Inspection Program
CONTINUED AIRWORTHINESS
AIRFRAME PERIODIC INSPECTION
1. Introduction Powerplant - Area 5 (ref. Table 205)
The rotorcraft is divided into 7 different Baggage compartment - Area 6 (ref.
inspection areas. The airframe periodic Table 206)
inspection includes inspections for these 7
areas and the landing gear (ref. Figure 201), Tailboom and empennage - Area 7 (ref.
and general and final requirements: Table 207)
General (ref. Table 201) Landing gear (ref. Table 208)
Nose section and cockpit - Area 1 (ref. Final inspections (ref. Table 209)
Table 202) Make a copy of each table for your inspection
Cabin compartment - Area 2 (ref. records. Put your initials on the record after
Table 203) successful completion of each task. At the end
of each table is a signature block for certifica
Upper transmission deck and main rotor - tion of each airframe periodic inspection and
Areas 3 and 4 (ref. Table 204) continued airworthiness.
9G05-001
1. NOSE SECTION AND COCKPIT 5. POWERPLANT
2. CABIN COMPARTMENT 6. BAGGAGE COMPARTMENT
3. UPPER TRANSMISSION DECK 7. TAILBOOM AND EMPENNAGE
4. MAIN ROTOR 8. LANDING GEAR
Page 201
Table 201. Airframe Periodic Inspection General

900 Fully clean rotorcraft and engines before you start inspection. CSPSPM
202000
900 During operation in a corrosive environment, make sure the rotorcraft CSPSPM
has a daily rinse and a wash every 14 days 202000
900 Refer to related manufacturers publications for detailed necessary 010000
inspection of engines, starter/generators, battery, and all installed
STC and optional equipment.
900 Examine the rotorcraft maintenance records for rotorcraft N/A
discrepancies and correct as necessary.
900 Examine Integrated Instrument Display System (IIDS) Exceedance 953000
Log Menu and Fault Log Menu. Record and correct discrepancies as
necessary.
NOTE: Logs may be viewed on the IIDS or refer to GBMC User Guide
for complete download and save of IIDS data.
900 Make sure you comply with component mandatory retirement. Refer 040000
to Airworthiness Limitation Schedule and make entries in the
Rotorcraft Log Book.
900 Make sure you comply with component overhaul. Refer to the 051000
Overhaul Schedule and make entries in the Rotorcraft Log Book.
900 Make sure you comply with applicable Special Inspections (Hourly 052010
and Calendar) and make entries in the Rotorcraft Log Book.
900 Make sure you comply with all applicable Airworthiness Directives N/A
and service bulletins and make entries in the Rotorcraft Log Book.
900 Make sure all placards and markings are installed. 110000
900 Defuel rotorcraft (if necessary) 120000
NOTE: Make sure helicopter is defueled before you remove a cabin
floor or floor access panel.
900 Remove trim panels, covers, and access panels as necessary. 060000
Airframe Periodic Inspection Certification General

I certify that this aircraft has been inspected in accordance with Airframe Periodic Inspection requirements and
is determined to be in an airworthy condition.
Signature
Rating Type or Certification No.
Date
Page 202
Table 202. Airframe Periodic Inspection Area 1, Nose Section and Cockpit (Cont.)

Fuselage
900 Examine cockpit windscreens for condition, security, and damage. 531000
900 Examine area fuselage exterior panels, and structure that is in view 531000
for damage, deterioration, and distortion. 532000
900 Examine cockpit floor panels for damage, condition, and attach 532000
hardware for correct installation and security.
900 Examine crew compartment for loose equipment and correct stowage 251000
of fire extinguisher, first aid kit, and other auxiliary equipment. 256000
262010
900 Examine crew seats and floor attach fittings for condition and security 251000
of attach hardware. Do a check of the crew seat adjustment for
correct operation.
900 Examine crew restraints for condition and security of attachment to 251000
seats. Do a check of the belt adjusters, buckles, and inertia reels for
correct operation.
900 Examine crew compartment interior trim for condition and security of 251000
attachment.
Doors
900 Examine left and right crew doors: 520000
For condition and damage
Door seals for condition and damage
Attach hardware and components for damage and security.
900 Do a check of crew door latch mechanisms for correct operation. 520000
900 Examine crew door windows and seals for condition, damage, and 520000
correct installation.
Flight Controls
900 Examine collective, cyclic, and antitorque flight controls brackets, 671000
bellcranks, links and control rods located under the cockpit floor, and 671020
in the controls closet for condition, indication of interference, correct 672000
installation, and control rod bolts installed in the correct direction.
Engine Controls
900 Examine mechanical engine control interconnect cables, detent 760000
modules, and area control cables for condition and correct
installation.
900 Do the Engine Controls Operational Test. 760000
Page 203

Environmental Control System

900 Examine crew gaspers for correct operation and installation. 212000
If optional heat/defog system is installed:
900 Examine heat/defog system: 214000
Valve for condition and security
Ejector and ducts for condition and security.
900 Do a check of crew heater control cable for correct operation. 214000
Fuel System
900 Do the Fuel ShutOff Valve Operational Test. 280000
900 Do the Crossfeed ShutOff Valve Operational Test (900 CONFIG). 280000
Fire Protection
If optional bleed air leak detection system is installed:
900 Examine detection control units and electrical connections for 261020
condition and security.
Instruments
900 Remove glare shield and top panel, and visually inspect: 950000
Glare shield and top panel for condition and damage 951000
952000
Installation of electrical wiring and instrument connections for and
condition, damage, and correct installation CSPSPM
Installation of pitotstatic tubing and connections for condition, 206000
damage, and correct installation.
900 Examine instrument panel and console structure for condition, 532000
damage, and security of attach hardware. 950000
900 Examine instruments for proper markings, condition, correct 951000
operation, and security. 952000
900 Examine area electrical wiring installation in forward section of 960000
console and installation of forward interconnect panel. and
CSPSPM
206000
900 Examine installation of console installed control panels and avionics 960000
equipment for correct markings, condition, and security.
Page 204

Electrical Power
900 Do the Exterior Lighting System Operational Test and Interior 964000
Lighting System Operational Test.
900 Examine nose area electrical wiring and electrical component 980000,
installation for condition, support, and security of attach hardware. and
CSPSPM,
206000
If battery is installed in the nose:
900 Examine battery installation: 961000
Battery case and cover for condition, damage, and attach
hardware for correct installation
Vent tubes for condition, damage, and correct installation
Power connection and temperature sensor connection for condition
and security.
900 Examine external power box or external power relay for condition, 960000
correct installation, wiring condition, and electrical connections.
Airframe Periodic Inspection Certification Area 1, Nose Section and Cockpit

Signature
Date
Page 205
Table 203. Airframe Periodic Inspection Area 2, Cabin Compartment (Cont.)

Fuselage
for damage, deterioration, and distortion. 533000
900 Examine cabin floor panels for condition, damage, and attach 532000
900 Examine cabin compartments for loose equipment and correct N/A
stowage of auxiliary equipment.
900 Examine cabin seats and attach fittings for condition and security of 252000
attach hardware.
900 Examine seat belts for condition and security of attachment to seats. 252000
Do a check of belt adjustors and buckles for correct operation.
900 Examine cabin compartment interior trim for condition and security. 252000
Doors
900 Examine left and right cabin doors: 520000
For condition and damage
Attach hardware and components for condition, damage, and
security.
900 Do a check for correct operation of: 520000
Cabin door latch mechanisms
Cabin door rollers.
900 Examine cabin door windows and attach seals for condition, damage, 520000
and correct installation.
Flight Controls
900 Examine area collective, cyclic, and antitorque flight controls 671000
brackets, bellcranks, links and control rods for condition, indication of 672000
interference, correct installation, and control rod bolts installed in the
correct direction.
900 Examine directional control servoactuator for correct installation, 672000
condition, too much fluid leakage, and security of connections.
900 Examine area hydraulic system tubes and flexible hoses for security 290000
of connections, support, condition, and security of attach hardware.
Engine Controls
900 Examine area mechanical engine control cables for condition and 760000
Page 206
Table 203. Airframe Periodic Inspection Area 2, Cabin Compartment (Cont.)


900 Examine cabin gaspers for correct operation and installation. 212000
900 Examine heat/defog system: 214000
Valve for condition and security
Ejector for condition and security.
900 Examine area bleed air tube installation for indication of bleed air tube 214000
failure, condition of insulation, and security of attach hardware.
900 Do a check of cabin heater control cable for correct operation. 214000
Fuel System
900 Do the Fuel Cell Leak Check/Pressure Test Method 1 or 2. 280000
Fire Protection
If optional bleed air leak detection system is installed:
900 Examine detection cable and cable attachments for condition and 261010
security.
Electrical Power
900 Examine area electrical wiring and electrical component installation 980000
for condition, support, and security of attach hardware.
Airframe Periodic Inspection Certification Area 2, Cabin Compartment

Signature
Date
Page 207
Table 204. Airframe Periodic Inspection Areas 3 and 4, Main Rotor and Upper Transmission
Deck (Cont.)
Fuselage
900 Examine area fuselage exterior panels, exterior surfaces of upper 533000
deck fairings and cowls, and structure that is in view for damage,
deterioration, and distortion.
Main Rotor
900 Examine main rotor blades: 621000

For damage and condition
Abrasion strip for security and bond condition
Examine the joint between the main rotor blade abrasion strips for
delamination.
900 Examine swashplate and attached components: 623000

Slider bearing journal on static mast for damage, condition, and
wear
Swashplate ball bearing for indication of grease leakage from the
lower grease seal.
900 Examine main rotor hub assembly: 622000

Damper caps for condition and security of installation
Striker plates and droop stop rollers for damage, condition, wear,
and corrosion
Pitchcases for damage and security of blade attach bushings and
blade attach hardware
Flexbeams for cracks, delamination, correct installation, security of
blade bushings and blade attach hardware
Centering bearings for damage and indication of deterioration.
Upper and lower hub for corrosion, cracks, and damage
Bolts for missing torque stripe and indication of fretting.
900 Examine for fluid on deck (except drain pans) indicating leakage.
900 Examine input drive shafts and NOTAR drive shaft: 631000
Flexible diaphragms and attach flanges for cracks, corrosion, and
damage
Attach hardware for security.
900 Examine exterior of transmission for condition and security of 632000

attached components.
Page 208
Deck (Cont.)

900 Examine exterior of oil cooler blower, oil cooler, interconnect, and 632100
cooling exhaust ducts:
For damage, condition and security of attach hardware
Inlet and outlet screens and interior of inlet and exhaust ducts for
foreign object damage (FOD).
900 Examine transmission lubrication system: 632100
Flexible hoses for leaks, damage, and security of connections
Transmission overboard drain hoses for indication of too much
leakage, condition, and security of connections.
900 Examine main rotor static mast and support trusses: 633000
Condition and correct installation
Visually inspect attach bolts for security
Areas of mast tube that are in view for corrosion, the area between
the swashplate and main rotor head is very important.
If optional rotor brake system is installed:
900 Examine rotor brake: 632200
Head for leakage and security of installation
Disc for wear and security of attach hardware
Wear groove indicator for indication of too much lining wear
Control valve for leakage and security of installation.
Powerplant
900 Examine forward left and right engine tubes for fluid leaks, condition, 717000
and security of connections and supports. 790000
900 Examine left and right forward engine firewall to plenum seals for 716000
condition and security of fire seal clamp.
900 Examine left and right forward engine mounts for damage, condition, 712000
indication of failure, and security of attach hardware.
If optional generator cooling modification is installed:
900 Do the Generator Cooling Duct and Screen Inspection. 716000
Engine Oil System

900 Examine left and right engine oil hoses and accessory pad drain 790000
tubing for leaks, condition, and security of connections.
Flight Controls
900 Examine collective, cyclic, and antitorque flight controls brackets, 671000
bellcranks, links and control rods located on the upper deck for 672000
condition, indication of interference, correct installation, and control
rod bolts installed in correct direction.
Page 209
Deck (Cont.)

900 Examine lateral, longitudinal, and collective servoactuators for 671000
correct installation, condition, too much fluid leakage, and security of
hose connections.
Engine Controls
900 Examine mechanical linkage to FMU for condition, correct installation, 760000
and security of attach hardware.
900 Examine mechanical engine control boxes, control cables, and 760000
adapter plates for condition and correct installation.
NACA Inlet
900 Examine NACA inlet for condition and security. 716000
if Inlet Particle Separator is installed:
900 Examine NACA inlet: 716000
Door for impact or other damage and condition of seal
Door actuator for condition and security
Door linkage for condition and security
Electrical connector and wire harness for condition and security.

900 Examine air vent system: 212000
Water separator and attached ducts for condition and security
Fan, forward fan mount, and aft fan mount for condition and
attached hardware for security.
If optional airconditioning system is installed:
900 Examine airconditioning system: 215000
Compressor and attach hardware for condition and security
Do a check of compressor reduction gearbox oil level
Area tubes and tube insulation for condition and security
Evaporator and duct installation for condition and security
CURRENT CONFIG Condenser and condenser duct installations
for condition and security.
Fuel System
900 Examine left and right engine fuel feed hoses for leaks, indication of 280000
failure, condition, and security of connections to engines.
Page 210
Deck (Cont.)

Fire Protection
900 Examine area engine deck mounted fire/overheat detection system 261020
detection cable, grommets, brackets, and cable connectors for
900 Examine detection control units (installed in Area 6) and electrical 261020
connections for condition and security.
Hydraulic System
900 Examine hydraulic system tubes, flexible hoses, and pump case drain 290000
hoses for leaks, indication of failure, security of connections, support,
900 Examine System 1 / System 2 manifold/reservoir for leaks, condition, 290000
security. Do a check for correct fluid levels.
900 Examine System 1 / System 2 hydraulic pumps and pump case 290000
drains for leaks, condition, and security of installation.
900 Examine ground support equipment (GSE) panel and interconnecting 290000
tubes for leaks, condition, security of tube connections, support, and
security of attached hardware.
If optional hand pump is installed:
900 Examine hand pump for leaks, condition, and security of installation. 290000
900 Examine interconnecting tubes for leaks, indication of failure, security 290000
of connections, support, and security of attach hardware.
Electrical Power
for condition, support, and security of attached hardware.
Airframe Periodic Inspection Certification Area 3 and 4, Main Rotor and Upper Transmission
Deck
Signature
Date
Page 211
Table 205. Airframe Periodic Inspection Area 5, Powerplant (Cont.)

Fuselage
900 Examine fuselage exterior panels, exterior surfaces of upper deck 533000
fairings and cowls, and structure that is in view for damage,
Powerplant
900 Examine left and right inlet panels for condition and security of attach 716000
hardware.
900 Examine left and right engine tubes for fluid leaks, condition, and 717000
security of connections and supports. 790000
900 Examine left and right, aft engine firewall to plenum seals for 710000
condition and security of fire seal clamp.
900 Examine left and right aft engine mounts for condition, indication of 712000
failure, and security of attach hardware.
900 Do the Engine NP Overspeed Test Procedure in the applicable Rotorcraft
Rotorcraft Flight Manual. Flight Manual
If optional inlet particle separator system is installed:
900 Examine left and right engine inlet air particle separator panels for 716000
impact damage, condition, and security of attach hardware.
900 Examine left and right bypass doors and installations for condition 716000
900 Do the Inlet Plenum Inspection and Inlet Particle Separator 716000
Functional Test.
Engine Bleed Air

900 Examine bleed air closure plates on engines for correct installation 750000
If optional heat/defog or inlet particle separator system is installed:
900 Examine bleed air fittings on engines for correct installation and 750000
security of attach hardware.
Page 212
Table 205. Airframe Periodic Inspection Area 5, Powerplant (Cont.)

Engine Exhaust System

900 Examine left and right primary exhaust nozzles: 780000
Primary exhaust nozzle for damage and condition
Exhaust nozzle Vband clamp for correct installation and security.
900 Examine left and right engine secondary ejectors: 780000
Inlet, outlet, and interior for damage and condition
Insulation blankets for damage, condition, correct installation, and
security of lockwire
Mounting brackets for damage, condition, and security of attach
hardware.
For rotorcraft with PW206E or PW207E engines installed:
900 Examine primary exhaust nozzle assembly (Inconel): 780000
For cracks and defects.

900 Do the Heat/Defog System Leak Check Functional Test. 214000
Fire Protection
900 Examine area engine deck mounted fire/overheat detection system 261020
If optional fire extinguishing system is installed:
900 Examine fire extinguishing system engine compartment distribution 262000
tubes and supports for condition and security.
Electrical Power
Airframe Periodic Inspection Certification Area 5, Powerplant

Signature
Date
Page 213
Table 206. Airframe Periodic Inspection Area 6, Baggage Compartment (Cont.)

Fuselage
for damage, deterioration, and distortion.
900 Examine baggage floor panels for damage, condition, and attach 532000
Equipment/Furnishings
900 Examine baggage compartment interior trim for condition and security 255000
of attach hardware.
Door
900 Examine baggage door: 520000
For condition
Attachment hardware and components for condition and security.
900 Do a check of baggage door latch mechanism for correct operation. 520000
AntiTorque Assembly
900 Examine antitorque fan: 643000
Fan hub for cracks, corrosion, and security of installation
Blades for impact damage and condition
Areas of pitch plate that are in view and pitch plate rod end bearing
for condition and correct installation of components.
900 Examine felt metal seal: 643000
Correct fan blade tip clearance
Felt seal for indication of FOD damage.
900 Examine NOTAR drive shaft: 631000
other damage
Attachment hardware for security.
NOTE: Examine with a small mirror through counterweight arm clear-
ance holes in fan hub.
Flight Controls
900 Examine antitorque flight controls brackets, bellcranks, links and 672000
control rods for condition, indication of interference, correct
installation, and rod end bolts installed in the correct direction.

900 Examine baggage area bleed air tube installation for indication of 214000
bleed air tube failure, condition of insulation, and security of attach
hardware.
Page 214

Environmental Control System (Cont.)

If optional air conditioning system is installed:
900 EARLY CONFIG Examine condenser, refrigerant tubes, condenser 215000
attach hardware, and condenser blowers, for condition and security.
Fuel System
900 Do the Fuel Supply Vapor Shroud Leak Check/Pressure Test. 280000
If optional fuel drain catch cans are installed:
900 Examine fuel drain catch cans for condition and security. 717000
Fire Protection
900 Examine area detection cable and cable attachments for condition 261010
and security of installation.
900 Examine fire bottles and mounting brackets for condition and correct 262020
installation. Do a check for correct charge pressure.
900 Examine fire bottle discharge and crossflow tubes for condition and 262020
security of end connections.
Electrical Power
900 Examine generator control units for condition, correct installation, and 960000
security of electrical connections.
900 Examine electrical load center for correct installation, security, and 960000
correct installation of electrical wiring and connections.
for condition, support, and security of hardware.
900 Examine strobe power supply for condition and security. 964000
Page 215

Electrical Power (Cont.)
If optional aft battery installation is installed:
900 Examine (aft) battery installation: 961000
Battery case and cover for condition and damage, installation
Vent tubes for condition and correct installation
Electrical connections for condition and security.
900 Examine external power box or external power relay for condition, 960000
correct installation, and security of wiring and electrical connections.
Airframe Periodic Inspection Certification Area 6, Baggage Compartment

Signature
Date
Page 216
Table 207. Airframe Periodic Inspection Area 7, Tailboom and Empennage (Cont.)

Fuselage
900 Examine exterior surface of tailboom, fuselage attach frame, and 534000
empennage attach frames for damage, condition, and security of
attach hardware.
900 Examine horizontal stabilizer: 535500
Exterior surfaces for damage and condition
Attach frames for damage, condition, and security of attach
hardware
Elastomeric damping spring for damage, condition, and security of
attach hardware.
If horizontal damping spring component time is 2000 hours or greater:
900 Do the Elastomeric Damping Spring Condition Verification Test. 535500
900 Examine upper and lower endplates: 535500
Exterior surfaces for damage and condition
Attach hardware for security
For incorrect movement (wiggle).
900 Examine tailboom bumper for deformity, condition, and security. 534000
Flight Controls
900 Examine VSCS actuators, mounting brackets, control rods, and 672000
endplate cranks for condition, indication of interference, correct
900 Examine thruster and thruster components: 672000
Thruster sector, control pulleys, drum, cable, cable ends,
turnbuckles, brackets, and attach hardware for condition, correct
installation, corrosion, pitting, wear and security
Do a check for correct thruster cable tension, use tensiometer
Rotating cone and bearing race (on inside surface) for condition
Control bearings for freedom of rotation, outer races for wear (flat
spots), and security.
Page 217
Table 207. Airframe Periodic Inspection Area 7, Tailboom and Empennage (Cont.)

Flight Controls (Cont.)

Airframe Periodic Inspection Certification Area 7, Tailboom and Empennage

Signature
Date
Page 218
Table 208. Airframe Periodic Inspection Landing Gear

900 Examine forward and aft cross tubes, fuselage attach fittings, and 320000
saddle clamps for damage, indication of failure and condition:
Examine saddle clamp pads for too much extrusion and attach
hardware for security.
900 Examine side stops for damage and condition. Visually inspect: 320000
Attach hardware, adjust bolts, and stop pads for condition and
security
Bonding jumpers for condition and correct mechanical connection.
900 Examine forward spacer fittings for condition, indication of failure, and 320000
900 Examine dampers for leaks, condition, and security of attachment 320000
hardware. Do a check for correct fluid level, look at fluid level gauge. 120000
900 Examine skid tubes for damage and condition: 320000
Skid tube attach hardware for security.
900 Make sure forward and aft cross tube spread is in permitted limits. 320000
Airframe Periodic Inspection Certification Landing Gear

Signature
Date
Page 219
Table 209. Airframe Periodic Inspection Final Inspections

After Airframe Periodic Inspection

Touchup all damaged paint and exterior markings, as necessary.
Rotorcraft must not be moved or flown unless cockpit floor, cabin floor, and bag-
CAUTION gage floor panels are correctly installed. These are stressed panels.
Install all floor and access panels, covers, and trim panels removed or opened for inspection. Do a
check for closure, fit, and tightness. Make sure all loose equipment has been correctly put in
storage.
Do a check of all fluid levels. Fill fluid levels that are low. Make sure the filler caps are correctly
installed and are not loose.
Post Airframe Periodic Inspection RunUp

Ref. the latest revision of the applicable RFM for cockpit check and engine start procedures.
Airframe Periodic Inspection Certification Final Inspections

Signature
Date
Page 220
Section
052050
Airframe Segmented
Inspection Program
AIRFRAME SEGMENTED INSPECTION PROGRAM

ROUTINE INSPECTION
Table 201. Routine Inspection

General
900 Fully clean the rotorcraft as necessary before you start inspection. CSPSPM
202000
900 During operation in a corrosive environment, make sure there is a CSPSPM

daily rinse of the rotorcraft and a wash of the rotorcraft every 14 days. 202000
900 Ref. applicable manufacturer publications for detailed necessary 010000

inspection of engines, starter/generators, batteries, and all installed
STC and optional equipment.
900 Examine the aircraft maintenance records for aircraft discrepancies N/A
and correct as necessary.

necessary. (NOTE: Logs may be viewed on the IIDS or refer to
GBMC User Guide for complete download and save of IIDS data)
900 Make sure you comply with component mandatory retirement, refer to 040000
Airworthiness Limitation Schedule and make entries in the Rotorcraft
Log Book.
900 Make sure you comply with component overhaul, refer to Overhaul 051000
Schedule and make entries in the Rotorcraft Log Book.
900 Make sure you comply with applicable Special Inspections (Hourly 052010
and Calendar) and make entries in the Rotorcraft Log Book.
and service bulletins and make entries in the Rotorcraft Log Book.
Cockpit
900 Do an electrical function check of navigation, strobe, landing, 964000
instrument, utility, and universal lights.
900 Do an operational test of both fuel shutoffs. 280000

900 Do an operational test of cross feed valve (900 CONFIG). 280000
Engine Controls
900 Do a manual engine controls operational test. 760000
Page 201
Table 201. Routine Inspection (Cont.)

Right Side Fuselage
900 Examine the rotorcraft exterior for correct installation and condition, 530000
loose or missing rivets, cracks, tears, and punctures.
900 Examine the doors and access panels for correct installation and 532000
condition.
Right Landing Gear

900 Examine the forward landing gear side stop clamp. 320000
900 Examine the landing gear for correct installation and condition. 320000
900 Examine the landing gear dampers for correct servicing. 120000
Main Rotor
900 Examine the main rotor driveplate correct installation and broken or 631000
missing torque stripes.
900 Examine the main rotor flexbeams for cracks, delamination, and 622000
damage.
900 Examine the main rotor centering bearings for cracks and condition. 622000
900 Examine the main rotor blades and attach pins for correct installatin 621000
and condition.
900 Examine the for grease leaks around main rotor and swashplate 620000
bearings.
900 Examine the upper controls for correct installation and condition. 623000
Page 202

Right Transmission and Deck Area
900 Examine the transmission and deck area for:

Main rotor mast base, struts, and transmission attach points for 633000
correct installation and condition
Examine the bolts for correct installation 633000
Areas of main rotor mast tube that are in view for corrosion, the 633000
area between the swashplate and main rotor head is very
important
Rotor support attach points at deck for correct installation and 633000
cracks
Hydraulic manifold for leaks, fluid level, and filter impending bypass 290000
buttons
Hydraulic actuators for leaks and correct installation 671000
Hydraulic tubes and hoses for leaks, chafing, and correct 290000
installation
Engine and transmission oil cooling system for leaks and condition 790000
Transmission for correct oil level and condition 632100
Electrical wiring and connectors for correct installation, wear, and 632000
condition
Fluid on deck (except drain pans) that indicate leaks. 980000
900 Examine the NOTAR drive shaft: 631000

other damage
Correct installation.
900 Examine the input drive shaft for correct installation and broken or 631000
Right Engine and Deck Area
900 Examine the engine and deck for:

Engine oil level for correct quantity 120000
Engine oil filter impending bypass indicator 790000
Engine mounts 712000
Fuel and oil tubes and hoses for condition, leaks, and wear 710000
Loose or missing lockwire and cotter pins
All electrical wiring and connections for correct installation, wear,
and condition.
900 If installed, do a check of the airconditioning compressor for correct 215000

installation and condition.
Page 203

Tailboom and Empennage
900 Examine the tailboom for: 534000
Attach frame and hardware for correct installation and condition
Entire surface for delamination, cracks, and condition
and condition.
900 Examine the horizontal stabilizer for correct installation and condition. 535500
900 Examine the horizontal endplates for correct installation and 535500
condition.
900 Do an inspection of rotating cone for correct installation and freedom 672000
of movement. Remove rotating cone and do an inspection as follows:
Thruster sector, control pulleys, drum, cable, cable ends,
turnbuckles, brackets, and attach hardware for condition, correct
installation, corrosion, pitting, wear, and other damage
Make sure pulleys turn easily and smoothly
Rotating cone and bearing race (on inside surface) for condition
Control bearings turn freely, outer races for wear (flat spots) and
Install rotating cone.
Left Side Fuselage
900 Examine the rotorcraft exterior for correct installation and condition, 530000
loose or missing rivets, cracks, tears, and punctures.
900 Examine the doors and access panels for correct installation and 532000
condition.
Left Engine and Deck Area

900 Examine the engine and deck for:
Engine oil level for correct quantity 120000
Engine oil filter impending bypass indicator 790000
Engine mounts 712000
Fuel and oil tubes and hoses for condition, leaks, and wear 710000
Loose or missing lockwire and cotter pins
and condition.
Page 204

Left Transmission and Deck Area
900 Examine the transmission and deck area for:
Main rotor mast base, struts, and transmission attach points for 633000
correct installation and condition
Examine the bolts for correct installation 633000
Areas of main rotor mast tube that are in view for corrosion, the 633000
area between the swashplate and main rotor head is very
important
Rotor support attach points at deck for correct installation and 633000
cracks
Hydraulic manifold for leaks, fluid level, and filter impending bypass 290000
buttons
Hydraulic actuators for leaks and correct installation 671000
Hydraulic tubes and hoses for leaks, wear, and correct installation 290000
Engine and transmission oil cooling system for leaks, and 790000
condition 632100
Transmission for oil filter impending bypass indication, and 632000
condition
Electrical wiring and connectors for correct installation, wear, and 980000
condition
Fluid on deck (except drain pans) that is an indication of leaks.
900 Examine the NOTAR drive shaft: 631000

Flexible diaphragms and flanges for cracks, corrosion, and other
damage
Correct installation.
900 Examine the input drive shaft for correct installation and broken or 631000
Page 205

Left Transmission and Deck Area (Cont.)
If optional rotor brake system is installed:
900 Examine the rotor brake: 632200
Head for leaks and correct installation
Disc for wear, scratches, gouges, distortion and correct installation
Carrier and lining (pad) for indication of too much lining wear,
warping, and pitting
Control valve for leaks and correct installation.
Landing Gear
900 Inspect the landing gear for correct installation and condition. 320000
900 Inspect the landing gear dampers for correct servicing. 120000
Touchup all damaged paint as necessary.
Airframe Segmented Inspection Program Routine Inspection Certification
I certify that this aircraft has been inspected in accordance with the Airframe Segmented Inspection Program
Routine Inspection inspection requirements and is determined to be in an airworthy condition.
Signature
Date
Page 206
INSPECTION 1 NOSE SECTION AND COCKPIT

Table 202. Inspection 1 Nose Section and Cockpit (Area 1)

900 Make sure you comply with applicable Special Inspections (Calendar) 052010
for Area 1 and make entries in Log Book.
General
900 Fully clean helicopter as necessary before you start inspection. CSPSPM
202000
inspection of engines, starter/generators, battery and all installed STC
and optional equipment.
GBMC User Guide for complete download and save of IIDS data).
Airworthiness Limitation Schedule and make entries in Log Book.
Schedule and make entries in Log Book.
and service bulletins and make entries in Log Book.
Fuselage
900 Inspect area exterior and structure that is in view for damage, 532000
900 Inspect cockpit floor panels for damage, condition, and attach 532000
900 Inspect cockpit windscreens for condition, security, and damage. 531000
900 Inspect crew seats and floor attach fittings for condition and security 251000
of attach hardware. Do a check of the crew seat adjustment for
correct operation.
900 Inspect crew restraints for condition and security of attachment to 251000
seats. Do a check of the belt adjusters, buckles, and inertia reels for
correct operation.
900 Inspect crew compartment interior trim for condition and security of 251000
attachment.
Page 207
Table 202. Inspection 1 Nose Section and Cockpit (Area 1) (Cont.)

Doors
900 Inspect left and right crew doors: 520000
condition and damage
door seals for condition and damage
attach hardware and components for damage and security.
900 Do a check of crew door latch mechanisms and crew door hold open 520000
struts for correct operation.
900 Inspect crew door windows and seals for condition, damage, and 520000
Flight Controls
900 Inspect collective, cyclic, and antitorque flight controls brackets, 671000,
bellcranks, links and control rods located under the cockpit floor, and Section 1.,
in the controls closet for condition, indication of interference, correct Parts A., D.,
installation, and control rod bolts installed in the correct direction. & E.;
672000
Engine Controls
900 Inspect mechanical engine control interconnect cables, detent 760000
modules, and area control cables for condition and correct
installation.
900 Inspect crew gaspers for correct operation and installation. 212000
900 Inspect heat/defog system: 214000
valve for condition and security
ejector and ducts for condition and security.
900 Do a check of crew heater control cable for correct operation. 214000
Fire Protection
900 Inspect detection control units and electrical connections for condition 261020
and security.
Page 208

Instruments
900 Remove instrument panel glareshield and top panel. Visually inspect: 950000
glareshield and top panel for condition and damage 951000
952000
Installation of electrical wiring and instrument connections for CSPSPM
damage and correct installation 206000
Installation of pitotstatic tubing and connections for condition and
900 Inspect instrument and console structure for condition and security of 950000
attach hardware. 532000
900 Inspect instruments for correct markings, condition, correct operation, 951000
and security. 952000
900 Inspect installation of console installed control panels and avionics 960000
equipment for correct markings, condition, and security.
Electrical Power
900 Inspect nose area electrical wiring installation and installation of 980000
electrical panels for condition, security, support, and security of CSPSPM
hardware. 206000
If battery is installed in the nose:
900 Inspect battery installation 961000
battery case and cover for condition, and damage, and installation
vent tubes for condition and correct installation
power connection and temperature sensor connection for condition
and security.
900 Inspect external power box or external power relay for condition, 960000
Page 209

Helicopter must not be moved or flown unless cockpit floor, cabin floor and bag-
CAUTION gage floor panels are securely installed. These are stressed panels.
Install all floor and access panels, covers and trim panels removed or opened for inspection. Do a
check of all loose equipment for correct stowage.
Airframe Segmented Inspection Program Inspection 1 Certification

Inspection 1 inspection requirements and is determined to be in an airworthy condition.
Signature
Date
Page 210
INSPECTION 2 CABIN
Table 203. Inspection 2 Cabin (Area 2)

General
202000
900 Defuel helicopter (if necessary) 120000
NOTE: Make sure helicopter is defueled before you remove a cabin 060000
floor or floor access panel. If opposite panel is left installed, either
panel AR 165 or panel LR 165 can be removed without defueling
helicopter.
Fuselage
900 Inspect area fuselage exterior panels, and structure that is in view for 532000
damage, deterioration, and distortion. 533000
900 Inspect cabin floor panels for condition, damage, and attach hardware 532000
for correct installation and security.
Electrical Power
900 Inspect area electrical wiring and electrical component installation for 980000
condition, support, and security of attach hardware.
Page 211
Table 203. Inspection 2 Cabin (Area 2) (Cont.)

900 Inspect cabin compartment interior trim for condition and security. 252000
900 Inspect seat belts for condition and security of attachment to seats. 252000
Do a check of belt adjustors and buckles for correct operation.
Doors
900 Inspect left and right cabin doors: 520000

condition and damage
attach hardware and components for condition, damage, and
security.
900 Do a check for correct operation of: 520000

cabin door latch mechanisms
cabin door rollers
900 Inspect cabin door windows and attach seals for condition, damage, 520000
and correct installation.
Flight Controls
900 Inspect area collective, cyclic, and antitorque flight controls brackets, 671000,
bellcranks, links and control rods for condition, indication of Section 1.,
interference, correct installation, and control rod bolts installed in the Parts B., D.,
correct direction. & E.;
672000
900 Inspect directional control servoactuator for correct installation, 672000

condition, too much fluid leakage, and security of connections.
Engine Controls
900 Inspect area mechanical engine control cables for condition and 760000
900 Inspect cabin gaspers for correct operation and installation. 212000
900 Inspect heat/defog system: 214000

valve for condition and security
ejector for condition and security
900 Do a check of cabin heater control cable for correct operation. 214000
Page 212
Table 203. Inspection 2 Cabin (Area 2) (Cont.)

Fire Protection
900 Inspect detection cable and cable attachments for condition and 261010
security.
Fuel System
900 Do the fuel cell leak/pressure test 280000

Signature
Date
Page 213
Page 214
INSPECTION 3 MAIN ROTOR AND UPPER TRANSMISSION

DECK
Table 204. Inspection 3 Main Rotor and Upper Transmission Deck (Area 3 and 4)

for Area 3&4 and make entries in the Rotorcraft Log Book.
General
202000


Fuselage
900 Examine the area fuselage exterior panels, exterior surfaces of upper 531000
deck fairings and cowls, and structure that is in view for damage, 532000
deterioration, and distortion. 533000
Main Rotor
900 Examine the main rotor blades: 621000

Abrasion strip for security and bond condition
Do an inspection of the joints between the main rotor blade
abrasion strips for delamination.
Page 215
Table 204. Inspection 3 Main Rotor and Upper Transmission Deck (Area 3 and 4) (Cont.)

Main Rotor (Cont.)
900 Inspect swashplate and attached components: 621000

for damage and condition 633000
slider bearing journal on static mast for damage, condition, and
wear
swashplate ball bearing for indication of grease leakage from the
lower grease seal.
900 Inspect main rotor hub: 622000

striker plates and droop stop rollers for damage, condition, wear,
and corrosion
pitchcases for damage and security of blade attach bushings and
blade attach hardware
flexbeams for cracks, delamination, correct installation, security of
blade bushings and blade attach hardware
damper caps for condition and security of installation
upper and lower hub for damage and corrosion
bolts for missing torque stripe and indication of fretting.
900 Inspect exterior of transmission for condition and security of attached 632000
components.
900 Inspect transmission lubrication system: 632100

flexible hoses for leaks, damage, and security of connections
transmission overboard drain hoses for indication of too much
leakage, condition, and security of connections.
900 Inspect exterior of oil cooler blower, oil cooler, interconnect, and 632100
cooling exhaust ducts:
for damage, condition and security of attach hardware
inlet and outlet screens and interior of inlet and exhaust ducts for
FOD.
Flight Controls
900 Examine collective, cyclic, and antitorque flight controls brackets, 671000,
bellcranks, links and control rods located on the upper deck for Section 1.,
condition, indication of interference, correct installation, and make Parts C., G.,
sure the control rod bolts are installed in the correct direction. & H.;
672000
900 Examine lateral, longitudinal, and collective servoactuators for 671000,

correct installation, condition, too much fluid leakage, and security of Section 1,
hose connections. Parts C. & F.
Page 216

Hydraulic System
900 Inspect hydraulic system tubes, flexible hoses, and pump case drain 290000
hoses for leaks, indication of failure, security of connections, support,
900 Inspect System 1/System 2 manifold/reservoir for leaks, condition, 290000

security. Do a check for correct fluid levels.
900 Inspect Ground Support Equipment (GSE) panel and interconnecting 290000
tubes for leaks, condition, security of tube connections, support, and
If optional hand pump is installed:
900 Inspect hand pump for leaks, condition, and security of installation. 290000
900 Inspect interconnecting tubes for leaks, indication of failure, security 290000
of connections, support, and security of attach hardware.
Powerplant
900 Inspect forward left and right engine tubes for fluid leaks, condition, 717000
and security of connections and supports. 790000
900 Inspect left and right forward engine firewall to plenum seals for 710000
condition and security of fireseal clamp.
900 Inspect left and right forward engine mounts for damage, condition, 712000
indication of failure, and security of attach hardware.
If optional generator cooling modification is installed:
900 Do the Generator Cooling Duct and Screen Inspection. 716000

Engine Controls
900 Inspect mechanical linkage to FMU for condition, correct installation, 760000
900 Inspect mechanical engine control boxes, control cables, and adapter 760000
plates for condition and correct installation.
NACA Inlet
900 Inspect NACA inlet for condition and security. 716000

if Inlet Particle Separator is installed:
900 Inspect NACA inlet: 716000

door for impact or other damage and condition of seal
door actuator for condition and security
door linkage for condition and security
electrical connector and wire harness for condition and security.
Page 217

900 Inspect air vent system: 212000
Water separator and attached ducts for condition and security
Fan, forward fan mount, and aft fan mount for condition and attach
If optional air conditioning is installed:
900 Inspect air conditioning system: 215000
Do a check of compressor reduction gearbox oil level
Area tubes and tube insulation for condition and security.
Evaporator and duct installation for condition and security.
CURRENT CONFIG condenser and condenser duct installations
Fire Protection
900 Inspect area engine deck mounted fire/overheat detection system 261020
900 Examine detection control units (installed in Area 6) and electrical 261020
connections for condition and correct installation.
Electrical Power

Install all access panels, covers, and trim panels removed or opened for inspection.
Signature
Date
Page 218
INSPECTION 4 LANDING GEAR

Table 205. Inspection 4 Landing Gear

for landing gear area and make entries in the Rotorcraft Log Book.
General
200000
Airworthiness Limitation Schedule and make entries in Rotorcraft Log
Book.
Landing Gear
900 Inspect forward and aft cross tubes, fuselage attach fittings, and 320000
saddle clamps for damage, indication of failure and condition:
inspect saddle clamp pads for too much extrusion and attach
900 Inspect side stops for damage and condition. Visually inspect: 320000
attach hardware, adjust bolts, and stop pads for condition and
security
bonding jumpers for condition and correct mechanical connection.
900 Inspect forward spacer fittings for condition, indication of failure, and 320000
Page 219
Table 205. Inspection 4 Landing Gear (Cont.)

Landing Gear (Cont.)
900 Inspect dampers for leaks, condition, and security of attachment 320000
hardware. 120000
900 Make sure forward and aft cross tube spread is in permitted limits 320000
Signature
Date
Page 220
INSPECTION 5 POWERPLANT
Table 206. Inspection 5 Powerplant (Area 5)

General
202000

Fuselage
900 Inspect fuselage exterior panels, exterior surfaces of upper deck 533000
fairings and cowls, and structure that is in view for damage,
Fire Protection
900 Inspect area engine deck mounted fire/overheat detection system 261020
900 Inspect fire extinguishing system engine compartment distribution 262000

tubes and supports for condition and security.
Page 221
Table 206. Inspection 5 Powerplant (Area 5) (Cont.)

Powerplant
900 Inspect left and right inlet panels for condition and security of attach 716000
hardware.
900 Inspect left and right engine tubes for fluid leaks, condition, and 717000
security of connections and supports. 790000
900 Inspect left and right, aft engine firewall to plenum seals for condition 710000
and security of fireseal clamp.
900 Inspect left and right aft engine mounts for condition, indication of 712000
failure, and security of attach hardware.
If optional inlet particle separator system is installed:
900 Inspect left and right engine inlet air particle separator panels for 716000
impact damage, condition, and security of attach hardware.
900 Inspect left and right bypass doors and installations for condition and 716000
900 Do the Inlet Plenum Inspection and Inlet Particle Separator 716000
Functional Test.
Engine Bleed Air
900 Inspect bleed air closure plates on engines for correct installation and 750000
If optional heat/defog or inlet particle separator system is installed:
900 Do the Heat/Defog System Leak Check Functional Test. 214000

NOTE: If opposite panel is left installed, either panel AR 165 or panel 060000
LR 165 can be removed without defueling helicopter.
900 Inspect bleed air fittings on engines for correct installation and 750000
900 Inspect left and right primary exhaust nozzles: 780000

primary exhaust nozzle for damage and condition
exhaust nozzle Vband clamp for correct installation and security.
900 Inspect left and right engine secondary ejectors: 780000

inlet, outlet, and interior for damage and condition
insulation blankets for damage, condition, correct installation, and
security of lockwire
mounting brackets for damage, condition, and security of attach
hardware.
Page 222
Table 206. Inspection 5 Powerplant (Area 5) (Cont.)

Electrical Power

Signature
Date
Page 223
Page 224
INSPECTION 6 BAGGAGE COMPARTMENT

Table 207. Inspection 6 Baggage Compartment (Area 6)

General
202000
Fuselage
900 Inspect area fuselage exterior panels, and structure that is in view for 532000
damage, deterioration, and distortion. 533000
900 Inspect baggage floor panels for damage, condition, and attach 532000
900 Inspect baggage compartment interior trim for condition and security 255000
of attach hardware.
Door
900 Inspect baggage door: 520000
condition
door seals for condition and damage
attach hardware and components for condition and security.
900 Do a check of baggage door latch mechanism for correct operation. 520000
Page 225
Table 207. Inspection 6 Baggage Compartment (Area 6) (Cont.)

AntiTorque Assembly
900 Inspect felt metal seal: 643000
correct fan blade tip clearance
felt seal for indication of FOD damage.
AntiTorque Flight Controls

900 Inspect antitorque flight controls brackets, bellcranks, links and 672000
control rods for condition, indication of interference, correct
If optional air conditioning is installed:
900 EARLY CONFIG Inspect, condenser, refrigerant tubes, condenser 215000
attach hardware, and condenser blowers, for condition and security.
Fire Protection
900 Inspect area detection cable and cable attachments for condition and 261010
security of installation.

900 Inspect fire bottles and mounting brackets for condition and correct 262000
installation. Do a check for correct charge pressure.
900 Inspect fire bottle discharge and crossflow tubes for condition and 262000
security of end connections.
Fuel System
900 Do the Fuel Supply Vapor Shroud Leak Check/Pressure Test. 280000
If optional fuel drain catch cans are installed:
900 Inspect fuel drain catch cans for condition and security. 717000
Page 226
Table 207. Inspection 6 Baggage Compartment (Area 6) (Cont.)

Electrical
900 Inspect generator control units for condition, correct installation, and 960000
security of electrical connections.
900 Inspect electrical load center for correct installation, security, and 960000
correct installation of electrical wiring and connections.
900 Inspect strobe power supply for condition and security. 964000
condition, support, and security of hardware.
If optional aft battery installation is installed:
900 Inspect battery installation (Aft Installation): 961000
battery case and cover for condition and damage, installation
vent tubes for condition and correct installation
power connection and temperature sensor connection for condition
and security.
900 Inspect external power box or external power relay for condition, 960000

Signature
Date
Page 227
Page 228
INSPECTION 7 TAIL
Table 208. Inspection 7 Tail (Area 7)

General
202000
Empennage
900 Inspect empennage attach frames for damage, condition, and 534000
900 Inspect horizontal stabilizer: 535500
attach frames for damage, condition, and security of attach
hardware
elastomeric damping spring for damage, condition, and security of
attach hardware.
900 Inspect upper and lower endplates: 535500
attach hardware for security
for incorrect movement (wiggle).
900 Inspect tailboom bumper for deformity, condition, and security. 534000
If horizontal damping spring component time is 2000 hours or greater:
900 Do the Elastomeric Damping Spring Condition Verification Test. 535500
Page 229
Table 208. Inspection 7 Tail (Area 7) (Cont.)

AntiTorque/Directional Flight Controls
900 Examine VSCS actuators, mounting brackets, control rods, and 672000
endplate cranks for condition, indication of interference, correct
installation, and that rod end bolts are installed in the correct
direction.
900 Examine the thruster and thruster components: 672000
Do a check for correct thruster cable tension with a tensiometer
Electrical Power
for condition, support, and correct installation.
Signature
Date
Page 230
Section
055000
Continued
Airworthiness
Unscheduled
Inspection
CONTINUED AIRWORTHINESS UNSCHEDULED INSPECTION

1. General Permanent deformation of the landing gear
cross tubes more than permitted limits.
This section contains the unscheduled or
conditional inspections. You must do the The lower fuselage, lower tailboom surface,
necessary Rotorcraft Maintenance Manual or thruster to touch the ground.
(RMM) specific inspections and procedures
shown in the applicable table. Use the Level I inspection schedule in
Table 201 if you think there has been a hard
landing.
If there is an incident with your helicopter not
shown in this section, record all information If you find damage or deformation when you
regarding the incident and speak to the Field do the necessary maintenance and inspection
Service Department at MDHI, Mesa, Arizona. procedures, you must do the Level II inspec
Telephone 1-800-388-3378 or (480) tion and procedure schedule in Table 202.
346-6387. DATAFAX: (480) 346-6813 for
inspections and maintenance procedures you 3. Sudden Stoppage
need to do.
Sudden stoppage is a rapid deceleration of the
It is possible you will need to do more than one main rotor, rotor drive system, or anti-torque
of the inspections or procedures shown in the fan.
tables of this section. Do all inspections that
are applicable. A. Sudden Stoppage of the Main Rotor or
Rotor Drive System
NOTE: Refer to the applicable Pratt & Whitney
Canada (P&WC) maintenance manual (ref. Sudden stoppage of the main rotor and rotor
Section 01-00-00, Table 201) for necessary drive system is caused when the main rotor
inspections and procedures for conditions blades hit the ground, water, snow, thick
equivalent to those shown in this section. vegetation, or other object of sufficient mass to
cause deceleration. Sudden stoppage of the
main rotor and rotor drive system can also
WARNING occur during a hard landing if the blades hit
the fuselage or the tailboom. Use the inspec
All components, assemblies, or parts tion schedule in Table 203 after a sudden
that are removed for overhaul or re stoppage of the main rotor.
pair must be identified with the
cause for removal. B. Sudden Stoppage of the AntiTorque Fan
All other components, assemblies, or Sudden stoppage of the anti-torque fan is

parts that need to be replaced, must when damage is sufficient to make it neces
be discarded. sary to replace the fan blades. Use the
inspection schedule in Table 204 after a
sudden stoppage of the anti-torque fan.
2. Hard Landing
4. Overtorque
A hard landing is an incident or accident in
which the helicopter hits the ground with Overtorque is an incident in which the main
sufficient force to cause: rotor, drive system, or anti-torque fan torque
loads are more than the permitted limits. Use
Main rotor blade to hit the tailboom or the inspection schedules in Table 205 thru
upper fairings or cowlings. Table 210 when there has been an overtorque.
Page 201
NOTE: 7. Engine Out/Low Rotor Functional Check

The overtorque is recorded in the excee
dance log data from the integrated instru When major maintenance or a modification
ment display system (IIDS). has been done to the helicopter electrical
system, do the Engine Out/Low Rotor Check
The torque values shown in the IIDS data
(ref. the latest revision of the applicable
log are in the P&WC engine torque scale.
Rotorcraft Flight Manual (RFM)).
To get the equivalent transmission torque
value, multiply the engine torque by
1.242. 8. Unscheduled, Conditional Inspection
Tables
Under some overtorque conditions, time at
overtorque must be recorded in the Rotorcraft
(Ref. Table 201 thru Table 216)
Log Book:
Record single engine operation overtorque The tables for each inspection program/re
time as S1. quirement are divided into four columns:
Record twin engine operation overtorque
The first column (Model) shows the model of
time as T1.
helicopter the inspection or procedure is
Maximum overtorque total time is 5 hours. If applicable to.
S1 + T1 = 5 hours, main rotor transmission
must be overhauled. NOTE: The MD900 is the only model listed in
the Type Certificate Data Sheet (H19HM).
5. Overspeed The 902 is a configuration difference (ref.
Section 01-00-00, Aircraft Configuration).
Overspeed is an incident in which the rotor
speed (NR) is more than the limits shown in
the applicable Rotorcraft Flight Manual. Use The second column (Requirement) has a
the inspection schedules in Table 211 thru short description of the necessary inspection
Table 216 when there has been an overspeed. or procedure.
NOTE: The overspeed is recorded in the excee The third column (Ref. RMM Section) shows,
dance log data from the IIDS. if applicable, the manual or section that has
the specific inspection or procedure.
6. Lightning Strike
When you think there has been a lightning The fourth column (Initial) is for personnel
strike on the helicopter, speak to the Field to show they have done the necessary
Service Department at MDHI, Mesa, Arizona. inspection or procedure.
Telephone 1-800-388-3378 or (480)
346-6387. DATAFAX: (480) 346-6813 for All completed inspection schedules must be
inspections and maintenance procedures you kept as a permanent part of the helicopter
need to do. records.
Page 202
Table 201. Hard Landing, Level I, Conditional Inspection

Level I Initial inspection after a suspected hard landing. If no damage or deformation is found after these
inspections, no additional inspection is necessary. If damage and/or deformation is found during the these
inspections, do the Level II hardlanding conditional inspections (ref. Table 202).
Ref. RMM
Model Requirement Section Initial
900 Examine crew compartment for loose assemblies or parts, and for the 251000
correct stowage of equipment.
900 Examine passenger compartment and passenger seats for loose 252000
assemblies or parts.
900 Examine baggage compartment for loose assemblies or parts. 255000

Landing Gear
900 Examine cross tubes for apparent damage and permanent 320000
deformation.
Make sure the spread of crosstubes is not more than the permitted
maximum limits.
900 Remove Aft Crosstube Cover Assembly B230 (ref. Section 320000
060000) and examine aft crosstube for damage and permanent
deformation that is more than the permitted limits.
900 Examine landing gear dampers 320000
Examine exterior for damage and deformation
Examine for too much leakage
Examine fasteners for installation
900 Examine landing gear forward fitting spacers 320000
Examine for damage and deformation
900 Examine landing gear skids for damage and permanent deformation 320000
that is more than the permitted limits.
Page 203
Table 201. Hard Landing, Level I, Conditional Inspection (Cont.)
Ref. RMM
Fuselage
900 Examine upper deck fairings and cowlings: 533000
Examine for correct alignment and obvious damage
Examine installation of fasteners
900 Examine upper deck skin panels (transmission and engine bays) for 533000
deformation and buckling.
900 Examine upper deck mast fittings and adjacent area for damage or 533000
deformation.
900 Examine upper deck engine mount fittings and adjacent area for 533000
damage or deformation.
900 Examine underside of fuselage for signs of contact with the ground. 532000
900 Examine tailboom for damage: 534000
Examine lower surface for signs of contact with the ground
Examine upper surface for signs of rotor blade strike
900 Examine tailboom bumper: 534000

Examine for obvious damage and deformation
Examine fasteners and components to tailboom for damage and
deformation
900 Examine vertical and horizontal stabilizers: 535500
Examine components and fasteners for damage, deformation, and
installation
Examine mating or adjacent pivoting surfaces of vertical stabilizers
for signs of hard or inadvertent contact
900 Examine horizontal stabilizer damper: 535500
Examine for damage or deformation
Examine limiting pin for deformation and for signs of hard contact
with damper housing
Page 204
Ref. RMM
Main Rotor
900 Examine rotor blades: 621000
Examine blade tips for damage and signs of blade strike
Examine length of blade for blade skin buckling, cracks, and
indications delamination
900 Examine droop stop rollers and striker plates for damage and for 622000
signs of hard contact.

900 Examine transmission input drive shaft assemblies: 631000
Examine for obvious damage and installation
Examine hardware for installation
Examine for signs of movement at flanges
900 Examine antitorque fan drive shaft assembly: 631000
Examine for indications of movement at flanges
900 Examine truss strut assemblies: 633000
900 Examine truss strut deck attached fittings: 633000

900 Examine heat exchangers: 633000

Examine for obvious damage and deformation of heat exchangers
and mount brackets
AntiTorque Assembly
900 Examine blades of fan assembly for damage and signs of contact 643000
with felt seal.
Page 205
Ref. RMM
Flight Controls
900 Examine upper deck flight controls and rotating controls for obvious 671000
damage, deformation, and installation.
900 Do an operational test to make sure the controls move correctly. 671000
900 Examine the thruster cables, thruster cable support bracket, thruster 672000
control rod, and thruster control sector assembly for correct
installation, damage, and deformation.
900 Examine thruster for obvious damage or signs of contact with the 672000
ground.
900 Examine thruster stationary track and rotating cone followers for 672000
damage and deformation.
900 Do an operational test to make sure the directional controls and 672000
rotating cone move correctly.
Powerplant
900 Refer to related manufacturers publications for engine 010000
maintenance/inspection requirements.
900 Examine LH and RH engine mounts: 712000


900 Examine primary exhaust nozzle: 780000
Examine primary nozzle for damage and deformation
Make sure the clamp is correctly installed
900 Examine secondary exhaust nozzle: 780000

Examine secondary nozzle for damage or deformation
Make sure the secondary exhaust nozzle is correctly installed to
the aft firewall
Examine lower structural support for damage and deformation
Page 206
Ref. RMM
After Inspection
storage.
Post Inspection RunUp (If Applicable)

Page 207
Page 208
Table 202. Hard Landing, Level II, Conditional Inspection

Level II The Level II inspection is necessary if damage and/or deformation was found when you did the Hard
Landing Level I inspection.
NOTE: Some inspection items in the inspection that follows are directly related to specified types of damage
found during the Hard Landing, Level I, Conditional Inspection. Inspection items related to specified types of
damage are identified.
Ref. RMM
Model Necessary Inspection Section Initial
900 Do the crew Seat Energy Absorption System (EAS) Inspection. 251000
900 Examine crew restraints as follows: 251000
Examine for damage and make sure they are correctly attached
Do the Seat Restraint System Operational Test
900 Do the cabin Seat Energy Absorption System (EAS) Inspection. 252000
900 Examine passenger restraints as follows: 252000
Examine for damage and make sure they are correctly attached
Do the Seat Restraint System Operational Test
Fire Protection
If fire extinguishing system is installed
900 Examine fire bottles as follows: 262000
Examine fire bottles for damage
Examine brackets for damage and deformation
Make sure fasteners are tight.
900 Examine tubes as follows: 262000
Make sure connections are tight
Examine for indication of leakage.
Page 209
Table 202. Hard Landing, Level II, Conditional Inspection (Cont.)
Ref. RMM
Fuel System
900 Examine hoses as follows: 282000

Examine for damage

Make sure tube connections are tight
900 Examine frangible connections as follows: 282000

Examine for indication of leakage
Examine for indication of separation of frangible connection.
Hydraulic System
900 Examine hoses as follows: 291000

Examine for damage

Make sure swaged and/or threaded connections are tight
900 Examine servo actuators as follows: 291000

Examine for damage
Make sure fasteners are tight
Examine for too much leakage.
900 Examine hydraulic manifolds as follows: 291000

Examine for damage
Make sure fasteners are tight
Examine for too much leakage.
Page 210
Ref. RMM
Landing Gear
If permanent deformation of one or both landing gear cross tubes is more than permitted limits
900 Remove aft dampers: 320000

Examine fasteners for damage and deformation
Examine damper installation holes for damage or deformation
If you do not see damage to damper fastener holes, do a CSPSPM
fluorescent penetrant or dye penetrant inspection. 209000
900 Remove forward fitting spacers: 320000

Examine components and fasteners for damage and deformation
Examine forward fitting spacer fastener holes for damage or
deformation
If you do not see damage on forward fitting spacer fastener holes, CSPSPM
do a fluorescent penetrant or dye penetrant inspection. 209000
If permanent deformation of one or both landing gear cross tubes has occurred
900 Remove both forward and aft side stops: 320000

Examine side stops for damage or deformation
If you do not see damage on side stops, do a fluorescent penetrant CSPSPM
or dye penetrant inspection. 209000
900 Remove forward and aft saddle clamps: 320000

Examine saddle clamps for damage and deformation
If you do not see damage on saddle clamps, do a fluorescent CSPSPM
penetrant or dye penetrant inspection. 209000
900 If removed cross tube shows no permanent deformation more than 320000
permitted limits:
Examine for an indication it touched fuselage fittings and saddles
Examine forward fitting spacer and damper holes for damage and
deformation
If you do not see damage, do a fluorescent penetrant or dye CSPSPM
penetrant inspection of cross tube. 209000
Page 211
Ref. RMM
Landing Gear (Cont.)
900 Examine skid tubes as follows: 320000

Examine skid tube bolt holes for damage or deformation
If you do not see damage, do a fluorescent penetrant or dye CSPSPM
penetrant inspection of skid tube. 209000
Fuselage
900 Examine canopy support structure as follows: 531000

Examine composite components for cracks and delamination
Examine bonded or riveted joints for separation.
900 Examine cockpit floor substructure and lower section of forward 531000
bulkhead as follows:
Examine metal components for damage and deformation
900 Examine baggage floor substructure and aft part of cross tube box for 532000
damage, separation of bonded or riveted joints, and deformation of
metal components:
900 Examine forward bulkhead structure as follows: 533000

Examine components for damage and deformation
Examine riveted joints for separation.
900 Examine Aframe assembly as follows: 532000

900 Examine aft bulkhead structure as follows: 533000

Page 212
Ref. RMM
Fuselage (Cont.)
900 Examine tailboom frame and adjacent structure for damage and 532000
deformation.
If bottom of fuselage shows an indication of contact with the ground
900 Examine landing gear fuselage fittings and adjacent structure as 532000
follows:
Examine riveted joints for separation
Make sure torque stripe across aft fuselage fitting and adjacent
structure is not broken.
900 Examine keel beams, fuel cell support ribs and adjacent structure, 532000
and cabin floor substructure as follows:
If upper deck fairings and cowlings, upper deck, static mast deck fittings and/or engine mount deck
fitting shows damage or deformation
900 Examine upper deck fairings, cowlings, and fittings as follows: 533000
Make sure parts are correctly aligned
Examine latches and latch strikers for damage and deformation
Examine flanges of composite components for cracks or damaged
fastener holes
Examine flanges of metal components for deformation and
damaged fastener holes
900 Examine engine air inlet plenums and installation points as follows: 533000
Examine bolted or riveted joints for separation.
Page 213
Ref. RMM
Fuselage (Cont.)
If upper deck fairings and cowlings, upper deck, static mast deck fittings and/or engine mount deck
fitting shows damage or deformation
900 Examine firewall panels and installation points as follows: 533000

Examine bolted or riveted joints for separation.
900 Examine upper deck substructure as follows: 533000

900 Examine upper deck mast fittings and installation points: 533000
Examine fittings for damage and deformation
900 Examine upper deck engine fittings as follows: 533000

Examine fittings for damage and deformation
If tailboom, tail bumper, and/or thruster shows damage

900 Remove tailboom and examine tailboom frame as follows: 532000
Examine tailboom frame for damage, deformation, and damage to
fastener holes
Examine fasteners for damage or deformation
Examine adjacent area fuselage panels and aft deck skin for
cracks, deformation, and damage to fastener holes
If you do not see damage, do a dye penetrant inspection of aft CSPSPM
surface of tailboom frame. 209000
Main Rotor
If main rotor blades or main rotor hub shows damage
900 Do the Main Rotor Sudden Stoppage, Conditional Inspection. 055000
Page 214
Ref. RMM
If main rotor blades or main rotor hub shows damage; and/or transmission input, and/or antitorque
drive shaft shows damage or an indication of movement at flanges
900 Do the Main Rotor Sudden Stoppage, Conditional Inspection. 055000
AntiTorque Assembly
If fan blades show damage and/or an indication of contact with felt seal
900 Do the AntiTorque Fan Sudden Stoppage, Conditional Inspection. 055000
Flight Controls
If main rotor blades or main rotor hub shows damage

900 Examine hydraulic servoactuators as follows: 671000
Examine for indication of too much leakage
Examine piston rods for damage or deformation
Make sure they are correctly attached.
900 Remove access covers and examine all upper deck linkages, 671000
bellcranks, control rods, and support brackets as follows:
Make sure rod end bearings and hardware is correctly attached
Make sure linkages, bellcranks, and control rods move freely.
900 Remove cockpit access covers and floor panels. Examine all 671000
linkages, bellcranks, control rods, and support brackets:
Make sure rod end bearings and hardware are correctly attached
Make sure linkages, bellcranks, and control rods move freely.
Powerplant
900 Refer to related manufacturers publications for necessary engine 010000
maintenance/inspection.
900 Examine left and right engine firewall seals for damage. 710000
900 Make sure left and right engine firewall seals are correctly attached. 710000
900 Do the Engine to Transmission Alignment. 710000
Page 215
Ref. RMM
Powerplant Controls
900 Do the Engine Controls Operational Test. 760000
After Hard Landing Level II Inspection
Touchup all damaged paint, external marks and placards, as necessary.
storage.

Page 216
Table 203. Main Rotor Sudden Stoppage, Conditional Inspection

Ref. RMM
Hydraulic
900 Remove hydraulic pump assemblies and examine hydraulic pump 290000
drive spline for damage or deformation.
900 Examine servo actuator assemblies: 291000

Examine actuator rods and rod ends for damage and deformation
Examine components and fasteners for correct installation
Fuselage
900 Examine upper deck fairings and cowlings for damage. 533000
900 Examine upper deck mast fittings and adjacent structure for damage 533000
and deformation.
900 Examine upper deck engine mount fittings and adjacent structure for 533000
900 Examine upper deck substructure for damage, deformation, and 533000
separation of riveted joints.
Main Rotor
900 Remove and examine main rotor blades: 621000

Examine skin for buckling and cracks
Examine for signs of skin delamination
Examine bosses for cracks and delamination
Examine flanged bushings for damage and installation
Examine retention bolts for damage or deformation
900 Remove and examine pitch links: 622000

Examine bearings for damage and installation
900 Remove and examine damper caps: 622000

Examine pitchcase installation holes for damage
900 Remove and examine main rotor dampers for damage and 622000
delamination of elastomer.
Page 217
Table 203. Main Rotor Sudden Stoppage, Conditional Inspection (Cont.)

Ref. RMM
Main Rotor (Cont.)
900 Remove and examine pitch cases: 622000
Examine for cracks and delamination
Examine outboard lug bushings for damage and installation
Examine pitch horns for damage, deformation, and installation
900 Remove and examine centering bearings: 622000
Examine snubber bolts for damage or deformation
900 Examine flex beams: 622000
Examine blade bushings for damage and installation
Examine for signs of hard contact with main rotor hub
Examine upper and lower main rotor hub assemblies for cracks
and deformation
Examine for installation of hardware
900 Remove and examine drive link assembly: 672000
Examine for damage and deformation, correct freedom of
movement
Examine installation hardware for damage and deformation
Examine bosses on lower hub and swashplate
900 Examine swashplate assembly: 622000
Examine pitchlink lugs for damage, deformation, and correct
installation of bushings
Make sure there is correct freedom of movement of rotating and
stationary swashplate subassemblies
Make sure there is correct freedom of movement of swashplate
assembly on static mast
900 Remove and examine link assemblies: 622000
Examine installation hardware for damage or deformation
Make sure there is correct freedom of movement and bearings are
correctly installed
Page 218

Ref. RMM
Main Rotor (Cont.)
900 Examine mixer assembly: 622000
Examine drive link lugs for damage or deformation
Make sure there is correct freedom of movement
Examine mixer pivot support assemblies for damage, deformation,
and installation of hardware

900 Remove and examine main rotor drive shaft: 631000
Do a magnetic particle inspection of drive shaft CSPSPM
209000
Do a magnetic particle inspection of hardware
900 Remove and examine main rotor drive plate: 631000
Do a magnetic particle inspection of drive plate CSPSPM
Do a magnetic particle inspection of hardware 209000
900 Remove and examine input drive shaft assemblies: 631000

Examine center section for damage and deformation
Examine flanges for deformation, elongation of fastener holes, and
correct installation of nutplates
Examine flexible couplings for cracks and deformation of
diaphragms
Examine flange of transmission input pinion assembly for
deformation and elongation of fastener holes
900 Remove and examine antitorque fan drive shaft assembly: 631000
correct installation nutplates
diaphragms
Examine flange of transmission output pinion assembly for
900 Do a manual rotation operational test of transmission. 632000
900 Remove and examine transmission installation hardware. 632000
900 Examine exterior perimeter of acoustic isolator for too much extrusion 632000
and cracks in elastomeric material.
900 Remove and examine cooling blower impellers: 632100
Examine hub for damage and deformation
Examine drive key and drive key slot in impeller hub for signs of
movement (shearing)
Page 219

Ref. RMM
Transmission and Drive System (Cont.)
Examine installation hardware for correct installation
900 Examine truss strut deck fittings: 633000
Examine installation hardware for correct installation
If main rotor drive shaft and/or a transmission drive shaft shows damage which makes the
component unserviceable
900 Remove transmission for overhaul. 632000
900 Remove and examine acoustic isolator: 632000
Examine for cracks and delamination of elastomeric material
Do a magnetic particle inspection of transmission fasteners CSPSPM
Do a dye penetrant inspection of coupling teeth on underside of 209000
mast base
AntiTorque Assembly
900 Remove antitorque inlet duct assembly (F2, ref. Section 060000) 640000
and examine fan support and adjacent structure for damage and
deformation.
900 Remove antitorque inspection door (F9, ref. Section 060000) and 640000
examine fan assembly blades for damage and signs of contact with
felt seal.
If antitorque fan blades show damage or signs of contact with felt seal
900 Do a conditional inspection in accordance with Unscheduled 055000
Maintenance, Conditional Schedule, Sudden Stoppage, AntiTorque
Fan.
Page 220

Ref. RMM
Flight Controls
900 Examine hydraulic servo actuators: 671000
900 Remove applicable covers and examine all upper deck linkages, 671000
bellcranks, control rods, and support brackets:
Examine rod end bearings and fasteners for correct installation
Make sure there is correct freedom of movement of linkages,
bellcranks, and control rods
Powerplant
900 Ref. related manufacturers publications, for detailed requirements on 010000
inspection of the engine.

Examine fasteners for correct installation
900 Make sure the engine to transmission alignment is correct. 712000

After Inspection
storage.

Page 221
Page 222
Table 204. AntiTorque Fan Sudden Stoppage, Conditional Inspection
Ref. RMM
Fuselage
900 Remove and examine antitorque fan inlet screen assembly for 533000
damage or deformation.
900 Examine upper inlet duct assembly (T240): 060000

Examine inlet screen assembly fastener holes and nutplates for 533000
damage and correct installation
Examine for FOD damage
900 Examine antitorque fan mounting frames and adjacent structural 532000
components for deformation and separation of riveted joints.
900 Examine fan support for impact damage, deformation, and correct 532000
installation.
900 Examine interior of tailboom for FOD damage. 534000
900 Remove and examine antitorque fan drive shaft assembly: 631000
installation of nutplates
diaphragms
If antitorque fan drive shaft shows signs of movement at flanges and/or damage which makes the
component unserviceable
900 Remove and examine input drive shaft assemblies: 631000

correct installation of the nutplates
diaphragms
900 Remove and examine cooling blower impellers: 632100

Examine hub for damage and deformation
Examine drive key and drive key slot in impeller hub for signs of
movement (shearing)
900 Remove and examine transmission installation hardware. 632000
Page 223
Table 204. AntiTorque Fan Sudden Stoppage, Conditional Inspection (Cont.)

Ref. RMM
Do a magnetic particle inspection (or replace) transmission CSPSPM
installation hardware 209000
Do a dye penetrant inspection of coupling teeth on underside of
mast base
AntiTorque Assembly
900 Remove and examine fan assembly access panels for FOD damage: 640000
Examine antitorque inlet duct assembly (F2) 060000
Examine center body fairing assembly (F3)
Examine lower center diffuser (F7)
Examine lower duct assembly (F8)
Examine lower section of stator assembly
900 Examine inlet assembly (F4): 640000
Examine for impact damage 060000
Examine overlap joint at inlet assembly (F4) and upper inlet duct
assembly (T240) for correct positioning and installation
900 Examine upper duct assembly (F5), upper center diffuser (F6), and 640000
upper section of stator assembly for FOD damage and correct 060000
installation.
900 Remove and examine fan drive coupling: 640000
Examine flange for damage, deformation, and elongation of
fastener holes
Examine spline for damage and deformation
Page 224

Ref. RMM
AntiTorque Assembly (Cont.)
900 Remove and examine pitch control shaft 640000
Examine control shaft for damage and deformation
Examine rod end bearing for correct freedom of movement and
installation
900 Remove and examine pitch change assembly: 640000
Examine assembly flange for damage, deformation, elongation of
fastener holes
Examine rod end bearing for correct freedom of movement and
installation
Make sure there is correct freedom of movement of bearing
900 Remove and examine fan assembly: 640000
Examine blades for impact damage, blade tips for damage and
signs of contact with felt seal, blade root and pitch horns for cracks
and deformation
Examine tensiontorsion straps for cracks, delamination, and
bushing installation
Examine fan hub and inner rim bushings for damage and
deformation
Examine pitch plate and pitch plate bushings for damage and
deformation
Examine all removed hardware for damage and deformation
900 Examine felt seal: 640000
Examine for FOD damage and signs of fan blade contact
900 Remove and examine fan support assembly: 640000
fastener holes
Examine mount flange on fan support for damage, deformation,
and elongation of fastener holes
Make sure there is correct freedom of movement of bearing
Examine components and fasteners for damage and deformation
Page 225

Ref. RMM
Flight Controls
900 Examine diverter plate assembly for FOD damage. 672000
900 Do an operational test of directional flight controls: 671010
Do a test with lower access panels removed and fan assembly not
installed
Make sure the movement of diverter plate assembly is correct
900 Examine thruster: 672010
Examine interior for FOD damage
Examine airfoils of thruster cascade for FOD damage
Examine opening and interior of rotating cone for FOD damage
After Inspection
storage.

Page 226
Table 205. Overtorque Up to 110% (average input), Conditional Inspection Both Engines
Operative
Ref. RMM
Comply with the requirements of the applicable Transmission and Drive System
CAUTION Overtorque Inspection in addition to these requirements.
Fuselage
900 Examine antitorque fan support for deformation and installation. 532000
900 Examine upper deck mast fittings and adjacent structure for obvious 533000
damage and looseness.
obvious damage and looseness.
Main Rotor
and deformation
900 Examine truss struts: 632000
Examine for fasteners for looseness
900 Examine drive link assembly: 672000
Examine for loose components and fasteners
Examine for obvious damage
Examine links for obvious damage and installation
Make sure the links have the correct freedom of movement
AntiTorque Assembly
900 Examine blades of antitorque fan assembly for damage and 643000
indications of contact with felt seal.
Page 227
Table 205. Overtorque Up to 110% (average input), Conditional Inspection Both Engines
Operative (Cont.)

Ref. RMM
Flight Controls
900 Examine upper deck flight controls for obvious damage, deformation, 671000
and installation.
900 Do an operational test to make sure the controls move correctly. 671000
900 Do an operational test to make sure the directional controls and 672000
rotating cone move correctly.
Powerplant
900 Refer to related manufacturers publications for engine 010000
maintenance/inspection requirements.
NOTE: Engine Overtorque is a separate exceedance recorded by the
IIDS. This record will be in engine torque%
900 Examine LH and RH engine mounts 712000
Examine for loose fasteners
After Inspection
storage.

Page 228
Table 206. Overtorque Above 110% (Average Input), Conditional Inspection Both Engines
Operative

Ref. RMM
Comply with the requirements of the applicable Transmission and Drive System
CAUTION Overtorque Inspection in addition to these requirements.
Fuselage
and deformation.
deformation and buckling
900 Examine antitorque fan mounting frames and adjacent structural 532000
components for deformation and separation of riveted joints.
900 Examine fan support for damage, deformation, and loose fasteners. 532000
Main Rotor
900 Remove and examine pitch links: 622000
900 Remove and examine damper caps: 622000
Examine pitchcase fastener holes for damage
900 Remove and examine main rotor dampers for damage and 622000
delamination of elastomer.
Page 229
Operative (Cont.)

Ref. RMM
Main Rotor (Cont.)
and deformation
Make sure the hardware is correctly attached
If a component examined above has damage or deformation which makes the component(s)
unserviceable
900 Do the Main Rotor Sudden Stoppage, Conditional Inspection (ref. 055000
Table 203).
AntiTorque Assembly
900 Remove and examine fan drive coupling: 640000
fastener holes
900 Examine mating drive coupling spline on fan support assembly for 640000
900 Examine fan assembly blades for damage and/or signs of contact 640000
with felt seal.
If fan drive coupling and/or drive spline on fan support assembly has damage which makes the
component unserviceable; and/or if fan assembly blades have signs of contact with felt seal
900 Do a conditional inspection in accordance with Unscheduled, 055000
Conditional Inspection, Sudden Stoppage, AntiTorque Fan.
Flight Controls
900 Remove applicable covers and examine all upper deck linkages, 671000
bellcranks, control rods, and support brackets:
Examine for loose rod end bearings and fasteners
Make sure there is correct freedom of movement of linkages,
bellcranks, and control rods
Page 230
Operative (Cont.)

Ref. RMM
Flight Controls (continued)
900 Remove applicable covers and examine all directional flight control 671010
components:
Do an operational test to make sure the control rods, linkages, and
bellcranks move correctly.
Powerplant
900 Ref. related manufacturers publications for engine inspection 010000
requirements.
NOTE: Engine overtorque is a separate exceedance recorded by the
IIDS. This record will be in engine torque percent.
After Inspection
storage.

Page 231
Page 232
Table 207. Transmission and Drive System Overtorque, Conditional Inspection, Single Engine
Operation

Ref. RMM
NOTE: If IIDS shows time above multiple thresholds, make sure which ones are actual exceedances. If more
than one, record longest one as S1 time in Rotorcraft Log Book.
125 to 139%
900 Log time above transmission input exceedance threshold as provided N/A
by the IIDS in the Rotorcraft Log Book (S1 value).
140 to 150%
900 Log time above transmission input exceedance threshold as provided N/A
900 Replace all input drive shaft fasteners. 631000

900 Examine transmission input flange for visible damage. If damaged, 632000
replace input pinion.
900 Examine transmission acoustic isolators for condition and installation. 632000
900 Examine transmission fasteners for condition and looseness. Make 632000
sure the torque is correct.
Above 150%
900 Replace input drive shaft and all fasteners. 631000
900 Replace transmission assembly. 632000
After Inspection
storage.

Page 233
Page 234
Table 208. Transmission and Drive System Overtorque (900 CONFIG), Conditional Inspection.
Both Engines Operative, 8% Maximum Engine Torque Differential

Ref. RMM
CAUTION
Each engine overtorque exceedance shall be evaluated as a single engine overtorque.
The combined engine overtorque shall be evaluated as an average of the two engine overtorques.
than one, record longest one as S1 time in Rotorcraft Log Book.
Single Input 125 to 139%

900 Log time above transmission input exceedance threshold value as N/A
provided by the IIDS in the Rotorcraft Log Book (S1 value).

provided by the IIDS in the Rotorcraft Log Book (S1 value).
900 Examine transmission fasteners for condition and looseness. Make 632000
Single Input Above 150%
Averaged Input 101 to 120%
900 No action required. N/A
provided by the IIDS in the Rotorcraft Log Book (T1 value).
900 Examine main rotor drive shaft and drive plate for cracked or broken 631000
spline teeth. If found replace:
Main rotor drive plate
Main rotor drive shaft
Main rotor drive plate cover and fasteners
Transmission assembly
All eight segmented acoustic isolators
Transmission fasteners
Page 235
Both Engines Operative, 8% Maximum Engine Torque Differential (Cont.)

Ref. RMM
Averaged Input 121 to 125% (Cont.)
900 Replace main rotor drive shaft if not PN 900D2436530101. 631000
900 Examine main rotor drive shaft PN 900D2436530101 631000
900 Replace main rotor drive plate fasteners. 631000
900 Examine transmission acoustic isolators for condition. 632000
900 Examine transmission fasteners. Make sure the torque is correct. 632000
900 Examine input drive shaft assemblies and fasteners for condition and 631000
looseness. Make sure the torque is correct.

900 Record time above transmission input exceedance threshold value as N/A
given by the IIDS in the Rotorcraft Log Book (T1 value).
900 Replace main rotor drive shaft if not PN 900D2436530101. 631000

900 Examine main rotor drive shaft PN 900D2436530101. 631000
900 Replace hardware that attaches main rotor drive plate. 631000
900 Magnetic particle examine main rotor drive plate for cracks or related CSPSPM
damage. If found replace:
Hardware that attaches transmission
900 Replace transmission bolt acoustic isolators and transmission 632000

fasteners.
900 Examine segmented acoustic isolators for condition. 632000

looseness. Make sure the torque is correct.
Page 236

Ref. RMM
900 Examine antitorque fan coupling for condition and installation. 631000
900 Examine transmission antitorque output coupling for condition and 632000
installation.
installation. Make sure the torque is correct.

provided by the IIDS in the Rotorcraft Log Book (T1 value).

fasteners.
900 Examine main rotor drive shaft and drive plate spline teeth for 631000
cracked or broken spline teeth. If found replace transmission
assembly and all eight segmented acoustic isolators.
900 Replace main rotor drive shaft, drive plate, drive plate cover, and 631000
related fasteners.
900 Remove and examine antitorque fan drive shaft, do not disassemble 631000
drive shaft assembly:
Examine coupling to shaft interface for damage or cracking.
Examine fastener holes for corrosion, elongation, and fretting.
Replace if a discrepancy is found.

900 Examine transmission antitorque output pinion flange and 643000
antitorque fan input flange for corrosion, hole elongation, and
fretting. Replace if a discrepancy is found.
900 Replace all antitorque drive shaft fasteners. 631000
900 If not replaced by single engine torque value, examine input drive 631000
shaft assemblies and fasteners for condition and installation. Make
Page 237

Ref. RMM
Averaged Input Above 140%
900 Replace main rotor drive shaft, drive plate, drive plate cover, and 631000
related fasteners.
900 Examine antitorque fan input flange for corrosion, hole elongation, 643000
and fretting. Replace if a discrepancy is found.
900 Replace all antitorque driveshaft fasteners. 631000

900 Replace transmission, all acoustic isolators, and related fasteners. 632000
After Inspection
storage.

Page 238
Both Engines Operative, 8% Maximum Engine Torque Differential

Ref. RMM
CAUTION
Each engine overtorque exceedance must be evaluated as a single engine overtorque.
The combined engine overtorque must be evaluated as an average of the two engine overtorques.
Pedal position in percent must be used to determine main rotor overtorque inspection requirements.
If pedal position at time of exceedance is not recorded, 900 CONFIG Transmission and Drive System
Overtorque inspection schedule must be used on 902 CONFIG rotorcraft.
than one, record longest one as S1 time in the Rotorcraft Log Book.

900 Record time above transmission input exceedance threshold as given N/A


900 Examine transmission fasteners for condition and installation. Make 632000
Single Input Above 150%


900 No action required. N/A

by the IIDS in the Rotorcraft Log Book (T1 value).
900 Examine transmission acoustic isolators for condition. 632000
900 Examine transmission fasteners. Make sure the torque is correct. 632000
Page 239

Ref. RMM
900 If recorded pedal position is greater than 30%, replace main rotor 631000
drive shaft, if not PN 900D2436530101.
900 If recorded pedal position is greater than 30%, examine main rotor 631000
drive shaft PN 900D2436530101
drive plate fasteners.
drive shaft and drive plate for cracked or broken spline teeth. If found
replace:
Transmission fasteners

fasteners.

900 Examine antitorque drive shaft and fasteners for condition and 631000
installation.
900 Examine antitorque fan coupling for condition and installation. 643000
900 Examine transmission antitorque output coupling for condition and 632000
installation.
Page 240

Ref. RMM
replace:
900 If recorded pedal position is greater than 25%, magnetic particle 631000
examine main rotor drive plate for cracks or related damage. If found
replace:
900 If recorded pedal position is greater than 25%, examine drive plate 631000
for:
Fastener hole elongation
Material displacement at or around fastener holes
Pitting or fretting around fastener holes
Corrosion
Replace if a discrepancy is found
900 If recorded pedal position is greater than 25%, replace drive plate 631000
fasteners.

fasteners.
Page 241

Ref. RMM
900 Examine transmission antitorque output pinion flange and 632000
antitorque fan input flange for corrosion, hole elongation, and 643000
fretting. Replace if a discrepancy is found.
replace:
900 If recorded pedal position is greater than 20%, do a magnetic particle 631000
inspection of the main rotor drive plate for cracks or related damage.
If found replace:
Page 242

Ref. RMM
for:
Corrosion
fasteners.
900 If recorded pedal position is greater than 45% and less than 80%, 631000
examine main rotor drive shaft and drive plate splines. If splines are
cracked or broken, replace:
replace:
Main rotor drive plate cover
Main rotor drive plate and cover fasteners
Page 243

Ref. RMM
replace:
for:
Corrosion
900 If recorded pedal position is greater than 16%, magnetic particle 631000
examine main rotor drive plate for cracks or related damage. If found
replace:
fasteners.
replace:
Page 244

Ref. RMM
Averaged Input 146% and Above
900 Replace drive plate fasteners. 631000
900 Replace main rotor drive shaft, if not PN 900D2436530101. 631000
900 Examine main rotor drive shaft PN 900D2436530101. 631000
900 Examine drive plate for: 631000

Corrosion
900 Do a magnetic particle inspection of the main rotor drive plate for 631000
cracks or related damage. If found replace:
900 If recorded pedal position is more than 38%, replace: 631000

Page 245

Ref. RMM
Averaged Input 146% and Above (Cont.)
After Inspection
storage.

Page 246
Table 210. Transmission and Drive System Overtorque, Conditional Inspection. Both Engines
Operative, Greater Than 8% Engine Torque Differential

Ref. RMM
CAUTION
For each single input fault, do the requirements of Table 207, Transmission and Drive System
Overtorque, Conditional Inspection Single Engine Operation.
Do the averaged input portion of the applicable Both Engines Operative Overtorque
Inspection (ref. Table 208 900 CONFIG and Table 209 902 CONFIG).
Single Input 136% or Above

After Inspection
storage.

Page 247
Page 248
Table 211. Main Rotor Overspeed, 109 to 110% NR, Power Off, Conditional Inspection

Ref. RMM
Main Rotor
900 Examine main rotor blades 621000

Examine blade for proper installation and obvious damage
Examine retention bolts for proper installation and looseness
900 Examine pitch links: 622000

Examine fasteners for proper installation and looseness
900 Examine main rotor dampers (via inboard ends of pitch cases) for 622000
signs of damage and/or delamination of elastomer.
900 Examine pitch cases: 622000

Examine exterior and inboard and outboard ends for obvious
damage
Examine pitch horns for obvious damage, deformation, and
installation
900 Examine centering bearings (via inboard ends of pitch cases) for 622000
900 Examine (borescope) flex beams: 622000

Examine inboard areas for signs of hard contact with main rotor
hub

Do an eddy current inspection of the upper hub assembly CSPSPM
209000
Examine lower main rotor hub assembly for cracks and
deformation
900 Examine drive link assembly and adjacent components and fasteners: 672000
Examine for obvious damage and deformation, and make sure
there is correct freedom of movement
Examine fasteners for proper installation and looseness

Examine pitch link lugs for obvious damage, deformation,
Make sure there is the correct freedom of movement of rotating
and stationary swashplate subassemblies
Make sure there is the correct freedom of movement of swashplate
Page 249
Table 211. Main Rotor Overspeed, 109 to 110% NR, Power Off, Conditional Inspection (Cont.)

Ref. RMM
Main Rotor (Cont.)
900 Examine link assemblies: 622000
Examine fasteners for correct installation and looseness
Make sure there is the correct freedom of movement
AntiTorque Assembly
with felt seal.
If fan assembly blades show signs of contact with felt seal

After Inspection

storage.

Page 250
Table 212. Main Rotor Overspeed, 106 to 110% NR, Power On, Conditional Inspection

Ref. RMM
Fuselage
900 Examine upper deck fairings and cowlings for obvious damage. 533000
900 Examine upper deck mast fittings and adjacent structure for obvious 533000

900 Examine main rotor drive plate for damage and deformation and 631000
fasteners for correct installation and looseness.
900 Examine input drive shaft assemblies: 631000

Examine flanges for deformation, and fastener installation
diaphragms
deformation

Examine flanges for deformation, and fastener installation
diaphragms
deformation
Page 251
Table 212. Main Rotor Overspeed, 106 to 110% NR, Power On, Conditional Inspection (Cont.)

Ref. RMM
Main Rotor
Examine blades for correct installation and obvious damage
Examine retention bolts for correct installation and looseness

900 Examine main rotor dampers (via inboard ends of pitch cases) for 622000
900 Examine pitch cases: 622000

Examine exterior and inboard and outboard ends for obvious
damage
Examine pitch horns for obvious damage, deformation, and
installation
900 Examine centering bearings (via inboard ends of pitch cases) for 622000
900 Examine (borescope) flex beams: 622000

Examine inboard areas for signs of hard contact with main rotor
hub
Do an eddy current inspection of the upper hub assembly CSPSPM
209000
deformation
Examine fastener installation
900 Examine drive link assembly and adjacent components and 672000
fasteners:
Examine for obvious damage and deformation, and make sure
there is correct freedom of movement
Page 252

Ref. RMM
Main Rotor (Cont.)

Examine pitch link lugs for obvious damage, deformation, and

AntiTorque Assembly
with felt seal.
If fan assembly blades exhibit signs of contact with felt seal

Powerplant
900 Refer to related manufacturers publications for engine inspection 010000

requirements

900 Make sure the engine to transmission alignment is correct 712000
After Inspection
storage.
Page 253

Ref. RMM
Page 254
Table 213. Main Rotor Overspeed, 111 to 114% NR, Power Off, Conditional Inspection
Ref. RMM
Main Rotor


900 Remove damper caps and examine main rotor dampers for damage 622000
and delamination of elastomer.

900 Examine centering bearings: 622000



Eddy current examine upper hub assembly CSPSPM
209000
deformation

Examine for damage and deformation, and make sure there is
correct freedom of movement
Examine bosses on lower hub and swashplate for damage and
deformation
Page 255

Ref. RMM
Main Rotor (Cont.)
Examine pitch link lugs for damage, deformation, installation of
bushings

Make sure there is correct freedom of movement and installation of
bearings

and installation of hardware

Examine surface along entire length of center section for removal
of black anodize, scratches, and signs of contact with surrounding
components.
Examine flanges for damage, deformation, and installation of
fasteners
Examine flexible couplings for scratches, cracks, and deformation
of diaphragms
Examine transmission output flange for damage or deformation
AntiTorque Assembly
with felt seal.
If fan assembly blades show signs of contact with felt seal

Page 256

Ref. RMM
After Inspection
storage.

Page 257
Page 258
Table 214. Main Rotor Overspeed, 111 to 114% NR, Power On, Conditional Inspection
Ref. RMM
Hydraulic
900 Remove hydraulic pump assemblies and examine hydraulic pump 290000
drive spline for damage or deformation.
Fuselage
900 Examine upper deck fairings and cowlings for damage. 533000
and deformation.
900 Examine input drive shaft assemblies: 631000

of paint, scratches, and signs of contact with surrounding
components
fasteners
of diaphragms
Examine transmission input flange for damage or deformation

of black anodize, scratches, and signs of contact with surrounding
components.
fasteners
of diaphragms
Examine transmission output flange for damage or deformation

Page 259

Ref. RMM
900 Remove and examine main rotor drive shaft: 631000

Do a magnetic particle inspection of drive shaft CSPSPM
209000
900 Remove and examine main rotor drive plate: 631000

Do a magnetic particle inspection of drive plate CSPSPM
209000

Replace bolt isolators and fasteners
Do a dye penetrant inspection of coupling teeth on underside of CSPSPM
mast base 209000
900 Do the manual rotation operational test of transmission. 632000

If main rotor drive plate, fasteners, and/or a transmission drive shaft shows damage which makes
the component unserviceable

Main Rotor

900 Remove damper caps and examine main rotor dampers for damage 622000
and delamination of elastomer.

Page 260

Ref. RMM
Main Rotor (Cont.)
900 Examine centering bearings: 622000



Do an eddy current inspection of the upper hub assembly
deformation

Examine for damage and deformation, and make sure there is the
correct freedom of movement
Examine bosses on lower hub and swashplate

Examine pitch link lugs for damage, deformation, and the bushings
are correctly installed

Make sure there is correct freedom of movement and the bearings
are correctly installed

Make sure there is the correct freedom of movement
and the correct installation of components and fasteners
Page 261

Ref. RMM
AntiTorque Assembly
with felt seal.
If fan assembly blades have signs of contact with felt seal

900 Do a conditional inspection (ref. Table 204). 055000
Flight Controls
Powerplant
900 Ref. the applicable manufacturer publications for engine inspection 010000
requirements.


After Inspection

storage.

Page 262
Table 215. Main Rotor Overspeed, Over 114% NR, Power Off, Conditional Inspection

Ref. RMM
Speak to MD Helicopters Field Service Representatives.
Page 263
Page 264
Table 216. Main Rotor Overspeed, Over 114% NR, Power On, Conditional Inspection

Ref. RMM
Speak to MD Helicopters Field Service Representatives.
Page 265
Page 266
Table 217. Main Rotor High Vibration During Startup or Shutdown At 35 To 40% NR

Ref. RMM
Do the Flexbeam Inspection. 622000
Page 267
Page 268
Chapter
DIMENSIONS AND AREAS

TABLE OF CONTENTS
06-00-00 Dimensions and Areas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A

1. Principal Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
2. Fuselage Stations, Waterlines, and Butt Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
A. Fuselage Stations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
B. Waterlines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
C. Butt Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
3. Inspection Areas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
4. Access Methods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
A. Access Item Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
B. Removal and Installation Methods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
C. Interior Trim Access Panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
D. Panel Removal for Scheduled Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
E. Stress Panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
Figure 201. Principal Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
Figure 202. Station Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
Figure 203. Inspection Areas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
Figure 204. Access Methods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
Figure 205. Nose Access Panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
Figure 206. Left Side Access Panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
Figure 207. Right Side Access Panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209
Figure 208. Top View Access Panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211
Figure 209. Bottom View Access Panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212
Figure 210. Stabilizer Access Panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213
Figure 211. Cabin Floor Interior Access Panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215
Figure 212. Pedestal Access Panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217
Figure 213. Fan Assembly Access Panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218
Page i

Page ii
Section
060000
Dimensions and
Areas
DIMENSIONS AND AREAS

1. Principal Dimensions 3. Inspection Areas
(Ref. Figure 201) (Ref. Figure 203)

The aircraft has been divided into seven
Principal dimensions of the helicopter with different inspection areas. Each area is
skid landing gear are shown in Figure 201. All addressed independently by the 100-hour or
height dimensions must be considered annual inspection and the continuous airwor
approximate, due to loading variations thiness maintenance program.
resulting in skid deflection. Ground handling
equipment installed on the skid gear will 4. Access Methods
increase the height approximately five inches.
(Ref. Figure 204)
Dimensions are given in feet (ft) and meters
(m) to accommodate international owners/op Doors, covers, panels, and fairings are located
erators. through out the airframe to provide access for
inspection, maintenance, and servicing.
Figure 204 is related to corresponding Figures
2. Fuselage Stations, Waterlines, and Butt
which list an access item number, access panel
Lines
names, what the panel permits access to,
fastener quantity, fastener type, and fastener
(Ref. Figure 202)
access method.
All dimensions shown in inches, are from A. Access Item Number
reference points designated as fuselage station
0.00, waterline 0.00, and butt line 0.00. Access Item Numbers indicate the nearest
attaching fuselage station. External and
A. Fuselage Stations internal doors, covers, panels and fairings are
shown in Figure 205 through Figure 213. Each
Fuselage stations (FS) are measured aft from door, cover, panel, and fairing has an item
fuselage station 0.00 along the longitudinal number designator letter and a number
axis of the helicopter fuselage. FS 0.00 is designator.
located 75.43 inches (191.59 cm) forward of
the helicopter nose. The 0.00 location is also (1). The letter indicates the location:
known as the reference datum line necessary (N) Nose
for weight and balance procedures. (L) Left Side
(R) Right Side
B. Waterlines (T) Top Side
(B) Bottom Side
Waterlines (WL) are horizontal planes (A) Cabin Floor (interior access)
perpendicular to, and measured along the (S) Stabilizer
vertical axis of the helicopter. WL 0.00 is (P) Pedestal (interior)
located 106.0 inches (269.24 cm) below the (F) Fan Assembly (interior)
cabin floor. (2). A combination of two letters may be
used to help identify a door, cover, panel
C. Butt Lines or fairing:
(PR) Pedestal Right
Butt lines (BL) are vertical planes perpendicu (PL) Pedestal Left
lar to, and measured to the left and right along
the lateral axis of the helicopter. BL 0.00 is the (3). L or R indicate doors, panels, and
plane at the vertical centerline of the helicop covers at the same station location:
ter. P(L/R)120.0.
Page 201
06-00-00 Original
B. Removal and Installation Methods C. Interior Trim Access Panels

(Ref. Figure 205 through Figure 213) Information on interior trim access panels is
provided in Ref. Section 25-00-00.
Use of power tools during re
CAUTION moval or installation of panels D. Panel Removal for Scheduled Inspection
and attaching hardware may damage nut
plates or deform holes in composite doors, The star sign () by an item number in a
covers, panels, and fairings. figure, indicates the minimum number of
panels to be removed or opened for an Air
Removal or installation of doors, covers, frame Periodic Inspection.
panels, and fairings is shown in the removal
and installation method column in each table, E. Stress Panels
with a supporting illustration. The type
column in each table lists the fastener and the The check sign () by an item number in a
quantity column lists the quantity used to figure, indicates the minimum number of
remove or install the door, cover, panel, and stress panels to be installed before moving the
fairing is listed. aircraft.
Page 202
Original 06-00-00
33.83 ft
(10.34 m)
DIAMETER
5.33 ft 9.33 ft
(1.62 m) (2.84 m)
5.91 ft
(1.80 m) 40.583 ft
(12.37 m)
12.0 ft
(3.66 m)
9.17 ft
(2.79 m)
10.91 ft
(3.32 m)
34.08 ft
7.33 ft (10.39 m)
(2.23 m) 1.25 ft
(0.38 m) 9G06-006D
Figure 201. Principal Dimensions
Page 203
60 80 100 120 140 160 180 200 220 240 260 280 300 320 340 360 380 400 420 440 460 480
60 60
40 40
20 20
- 20 - 20
- 40 - 40
- 60 - 60
60 80 100 120 140 160 180 200 220 240 260 280 300 320 340 360 380 400 420 440 460
5 0
STA 199.25
60 40 20 0 - 20 - 40 - 60
WL 207.97
220 220 220
200 200 200
180 180 STA 292.817 180

WL 147
160 160
140
WL 159
140
ROOF DECK
120 120 120
100 100 100

WL 106
80 FLOOR 80 80
60 60 60
3 16
STA 155.5 STA 230.5
FRAME FRAME
BL 8.5 BL 24
BEAM BEAM
9G06-007C
Figure 202. Station Diagram
Page 204
9G06-014
1. NOSE AND COCKPIT 4. MAIN ROTOR
2. CABIN 5. POWERPLANT (FORWARD FIRESEAL AND AFT)
3. UPPER TRANSMISSION DECK (FORWARD FIRESEAL 6. BAGGAGE
AND FORWARD) 7. TAIL (TAILBOOM ATTACH AND AFT)
Page 205
KEYLOC CAMLOC LATCH HINGE

UNLOCKED LOCKED
1/4
TURN
UNLOCK- UNLOCK- PUSH HERE

COUNTERCLOCKWISE COUNTERCLOCKWISE ROTATES 180 TO UNLOCK
LOCK-CLOCKWISE LOCK-CLOCKWISE TO UNLOCK
CAMLOC LATCH SLEEVE BOLT

UNLOCKED LOCKED LOCKED UNLOCKED
1/4
TURN
PUSH TO PUSH TO
UNLOCK LOCK
LEVER ACTION HANDLE HINGE PIN PIN SCREW CAMLOC
PULL TO RELEASE
DOOR PINS
BOLT
LATCH
UNLOCK-ONE ACTION LOCK-TWO ACTIONS
1 PUSH
HOOK-1
PULL
2 PULL
LIFT PUSH-2
TURN AND LOCK STRUT CAMLOC

LOCKED CLOSED UNLOCKED
PULL OFF
HERE
LIFT
HERE
9G06-008
Figure 204. Access Methods
Page 206
Original 06-00-00
N80
N82
N106
9G06-001A
Figure 205. Nose Access Panels
Legend (Ref. Figure 205)

Removal and Installation
Method
Item Ref.
No. Name Permits Access To Quantity Type Figure 204
N80 Nose Door Battery 2 Camloc B
1 Keyloc A
N82 Landing Light Window Landing Light, 18 Screw L

Panel Flight Control Rods,
Avionics Cooling Fan,
Wire Harness,
External Power Box
N106 Panel 30 Screw L
Page 207
06-00-00 Original
L220 L260
L210 L270
L155
L262
L166
L109 L210
L240
L107 L170 L211 NACA INLET
INSTALLATION
9G06 002B
Figure 206. Left Side Access Panels

Method
Item Ref.
L107 Crew Door, Copilot Instrument Panel, 1 Lever Action Handle H
Pedestal Console 1 Hinge Pin / Pin J, K
1 Strut End T
L109 Avionics Access Panel Electrical, Avionics, Flight 1 Keyloc A
Assembly, LH Controls 14 Camloc B
L155 Forward Access Door Main Transmission Access, 3 Latch C

Assembly, LH Flight Control Actuators, 2 Hinge D
Hydraulic Hand Pump, System N
1 Hydraulic Manifold/Reservoir
L166 Passenger Door, LH Passenger and Cargo 1 Lever Action Handle H

Compartment
L170 Access Panel Fuselage Tub outboard of 12 Camloc U

keelbeam
L211 Access Panel Fuselage Tub outboard of 12 Camloc U

keelbeam
L210 Transmission Access Main Transmission Access, 2 Hinge D

Door Assembly, LH Engine Reduction Gearbox 3 Latch C
SN010SN013 W/Out Housing N
NACA INLET

Door Assembly, LH Engine Reduction Gearbox 5 Camloc E
SN014051 W/Out Housing N
NACA INLET
Page 208
Legend (Ref. Figure 206) (Cont.)

Method
Item Ref.
Door Assembly, LH Engine Reduction Gearbox 5 Camloc E
UPPER W/ NACA Housing
INLET
L210 Transmission Access Main Transmission Access, 7 Camloc E

Door Assembly, LH Engine Reduction Gearbox
LOWER W/ NACA Housing
INLET
L220 Inlet Panel Assembly, Inlet, Engine Compressor 25 Fastener Sleeve Bolt G
LH (Engine Air)
L240 APU/EPR Door (AFT) Auxiliary / External Power 1 Camloc E

Receptacle
L260 Engine Cowling Engine, Engine Controls 10 Fastener Sleeve Bolt G

Assembly, LH
L262 Baggage Compart- Baggage Compartment, 1 Lever Action Handle H

ment Door behind trim panels; Engine
EECs, Wire Harness, ECS
Bleed Air Lines, Fuel Lines,
Drain Lines, Electrical Load
Center, Engine Fire
Extinguishing Bottles (optional)
L270 Exhaust Ejector Cowl Engine Exhaust 18 Machine Screw L
Assembly, LH
Page 209
R260 R220 R210

R270 R155
R107
R166
R210
NACA INLET R211
INSTALLATION
R185 R158 R128 R109
9G06-003A
Figure 207. Right Side Access Panels

Method
Item Ref.
R107 Crew Door, Pilot Instrument Panel, Pedestal 1 Lever Action Handle H
Consol 1 Pin Assembly J, K
1 Strut T
R109 APU/EPR Door Auxiliary / External Power 1 Camloc E
(FWD) Receptacle
R128 Avionics Access Panel Electrical, Avionics, Flight 1 Keyloc A

Assembly, RH Controls, ECS Bleed Air Lines 14 Camloc B
R155 Forward Access Door Main Transmission Access, 3 Latch C

Assembly, RH System 2 Hydraulic 2 Hinge D
Manifold/Reservoir N
R158 Fuel Cap and Adapter Fuel Filler Neck 1 Turn and Lock S
R166 Passenger Door, RH Passenger and Cargo 1 Lever Action Handle H
Compartment 1 Release Pin R
R185 Fuel Drain Access Fuel Sump Drain Control, 1 Camloc N

Panel Assembly Cables
R211 Access Panel Fuselage Tub outboard of 12 Camloc U

keelbeam
R210 Transmission Access Main Transmission Access, 2 Hinge D

Door Assembly, RH Transmission Oil Level and 3 Latch C
SN010SN013 W/Out Filler, Engine Reduction N
NACA INLET Gearbox Housing
Page 210

Method
Item Ref.
Door Assembly, RH Engine Reduction Gearbox 5 Camloc E
SN014051 W/Out Housing N
NACA INLET

Door Assembly, RH Engine Reduction Gearbox 5 Camloc E
UPPER W/ NACA Housing N
INLET
R210 Transmission Access Main Transmission Access, 7 Camloc E

Door Assembly, RH Engine Reduction Gearbox N
LOWER W/ NACA Housing
INLET
R220 Inlet Panel Assembly, Inlet, Engine Compressor 25 Sleeve Bolt G

RH (Engine Air) Section
R260 Engine Cowl Assem- Engine, Engine Controls 11 Sleeve Bolt G

bly, RH
R270 Exhaust Ejector Cowl Engine Exhaust 19 Machine Screw L

Assembly, RH
Page 211
T292
TR218
T240
T155 T220 TL218
9G06-009A
Figure 208. Top View Access Panels

Method
Item Ref.
T155 Swashplate Forward Hydraulic Servo Actuators, 19 Screw L

Fairing Assembly Swashplate, Mixer 4 Bolt M
TL218 Oil Dipstick Hand Engine Oil Level and Filler 1 Hinge Q
Hold, LH 2 Camlock E
TR218 Oil Dipstick Hand Engine Oil Level and Filler 1 Hinge Q
Hold, RH 2 Camlock E
T220 Swashplate Aft Fairing Mast Support, Transmission, 58 Screw L

Assembly Flight Controls, ECS, Engine 4 Bolt M
Oil Level and Filler
T240 Upper Inlet Duct Fan Driveshaft, Air Inlet To Fan 19 Screw L
Assembly 24 Bolt M
T292 Tailboom Upper Required Panel Removal T240, 7 Screw L

Fairing Assembly L270 and R270
Page 212
Original 06-00-00
B178
B142 B230
9G06-005
Figure 209. Bottom View Access Panels

Method
Item Ref.
B142 Center Access Panel Throttle Interconnect Cable, RH 14 Screw L
Assembly Collective
B178 Sump Access Panel Fuel Sump Drain Valves 22 Screw L

Assembly
B230 Crosstube Cover Landing Gear Crosstube Aft 30 Screw L

Assembly (Aft)
Page 213
06-00-00 Original
S6
SR7 SR5 SL7
SL5 S4
SR3
SR1
SL1 S2 SL3
SR8
WITHOUT THRUSTER EXTENSION
SL8
WITH THRUSTER EXTENSION
9G06-004B
Figure 210. Stabilizer Access Panels

Method
Item Ref.
SL1 Upper Tailboom/ Horizontal Stabilizer Mount 21 Screw L
Thruster Fairing Fitting Stationary Thruster
Assembly, Left Side Extension
SR1 Upper Tailboom/ Horizontal Stabilizer Mount 21 Screw L
Thruster Fairing Fitting, Stationary Thruster
Assembly, Right Side Extension
S2 Lower Tailboom/ Horizontal Stabilizer Mount 22 Screw L
Thruster Fairing Fitting Stationary Thruster
Assembly Extension
SL3 Outboard Fairing Vertical Stab Torque Tube, 13 Screw L
Assembly, LH Control Rod, Electrical Wiring,
(Endplate) Position Light
Page 214

Method
Item Ref.
SR3 Outboard Fairing Vertical Stab Torque Tube, 11 Screw L
Assembly, RH Control Rod, Electrical Wiring,
(Endplate) Position Light
S4 Thruster End Cover Attachment Bolts For Rotating 8 Screw L
Thruster
SL5 Center Access Cover, Wiring 10 Screw L

LH (Horizontal
Stabilizer)
SR5 Center Access Cover, Wiring 10 Screw L
RH (Horizontal
Stabilizer)
S6 Leading Edge Cover 10 Screw L
Center
SL7 Access Cover LH VSCS Actuator 10 Screw L

SR7 Access Cover RH VSCS Actuator 10 Screw L
SL8 Thruster Extension Thruster Extension 16 Screw L
Fairing Assembly, Left Thruster Mounting
Side
SR8 Thruster Extension Thruster Extension 16 Screw L
Fairing Assembly, Thruster Mounting
Right Side
Page 215
AR138 AR155 AR165 AR230 AR250
AR129
A235
AR145
AL138
AL230
AL129
AL155
A160 AL165 A170 A217 AL250
9G06-010A
Figure 211. Cabin Floor Interior Access Panels
Defuel the helicopter before you remove floor panels AL155, AR155, AL165, AR165,
CAUTION AL230, AR230, and A235. Damage to the structure can occur if you remove these
panels with fuel in the helicopter.

Method
Item Ref.
A160 Cabin Floor Forward Fuel Cell 69 Screw L
Panel Assembly
A170 Cabin Floor Center Fuel Cell 89 Screw L

Panel Assembly
A217 Cabin Floor Aft Panel Fuel Cell Aft Vent Rollover 75 Screw L
Assembly Valves
A235 Baggage Floor Center Crossfeed Valve, Condenser 64 Screw L

Panel Fans, Condenser
AL129 Cockpit Outboard Left LH Collective Stick Socket, 30 Screw L

Floor Panel Wire Harness, LH Static Port 1 Bolt M
AL138 Cockpit Floor Left Flight Control Tubes, Cyclic 24 Screw L

Access Panel Bellcrank 1 Bolt M
AL155 Cabin Floor Left Left Forward Fuel Vent Valve, 12 Screw L
Forward Access Fuel Cell
Cover
AL165 Cabin Floor Left Fuel Cell Frangible Valve, Wire 76 Screw L
Outboard Panel Harness
Page 216
Revision 7 06-00-00

Method
Item Ref.
AL230 Cabin Floor Left Aft Left Aft Fuel Vent Valve, Fuel 13 Screw L
Access Cover Cell
AL250 Baggage Floor Left Fuel Tee Fittings, Fuel Pressure 25 Screw L
Outboard Panel Switch Drain Tubing, Fuel Hose 4 Bolt M
Shrouds, Fuel Catch Can
AR129 Cockpit Outboard Fire Overheat Bleed Air Leak 34 Screw L
Right Floor Panel Control, Wire Harness, RH 1 Bolt M
Static Port
AR138 Cockpit Floor Right Flight Control Tubes, 35 Screw L
Access Panel Bellcranks, Throttle Cables
AR145 Pilots Collective Base Pilots Collective Base, Link 4 Screw L

Access Panel Assembly, and Mounting
Bracket
AR155 Cabin Floor Right Right Forward Fuel Vent Valve, 12 Screw L
Forward Access Fuel Cell
Cover
AR165 Cabin Floor Right Fuel Cell Frangible Valve, 76 Screw L
Outboard Panel Heat/Defog Bleed Air Line, Fire
Overheat Bleed Air Leak
Detector
AR230 Cabin Floor Right Aft Right Aft Fuel Vent Valve, Fuel 13 Screw L
Access Cover Cell
AR250 Baggage Floor Right Fuel Tee Fittings, Fuel Pressure 25 Screw L
Outboard Panel Switch Drain Tubing, Fuel Hose 4 Bolt M
Shrouds, ECS Tubing, Strobe
Power Supply, Fuel Catch Can
Page 217
06-00-00 Revision 7
PR120

PL120
9G06-012A
Figure 212. Pedestal Access Panels

Method
Item Ref.
PL120 Panel Wire Harness, Forward 9 Camloc U
Interconnect Panel (Relays),
Ground Modules
PR120 Panel Wire Harness, Forward 9 Camloc U
Interconnect Panel (TB2,
TB3,TB4)
Page 218
Original 06-00-00
F4
F5
F3 REF. STATOR
F6
F7
F9
REF. FAN SUPPORT AND
HOUSING
F8
F1 F2
9G06-013A
Figure 213. Fan Assembly Access Panels

Method
Item Ref.
F1 AntiTorque Drive Fan Drive Shaft 6 Screw L
Shaft Cover
F2 AntiTorque Lower Plenum Fan Assembly 19 Screw L

Inlet Duct Assembly 14 Bolt M
F3 AntiTorque Fan Fan Assembly, Fan Driveshaft 19 Screw L

Fairing/Center Body Coupling, Support Housing,
Assembly Fan Balance Monitor System
Magnetic Pickup and
Accelerometer
F4 AntiTorque Middle Fan Assembly Plenum air Inlet 4 Screw L
Inlet Duct Assembly 19 Bolt M
F5 AntiTorque Fan Plenum Air Inlet, Upper Stator 24 Screw L

Upper Duct Assembly Blades attached
F6 Upper Center Diffuser Upper Stator Blades attached 24 Screw L

F7 Lower Center Diffuser Fan Assembly and Diverter, 20 Screw L
Lower Stator Blades attached
Page 219
06-00-00 Original

Method
Item Ref.
F8 Lower Access Panel Diverter 4 Latch P
Assembly
F9 AntiTorque Fan Fan Assembly and Diverter, 18 Screw L

Lower Duct Assembly Fan Control Linkage
Page 220
Original 06-00-00
Page 221/(222 blank)

Chapter
LIFTING AND JACKING

TABLE OF CONTENTS
07-10-00 Lifting and Jacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A

1. Lifting and Jacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
A. Helicopter Hoisting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
B. Component Hoisting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
Table 201. Approximate Hoisting Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
Figure 201. Helicopter Hoisting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
C. Helicopter Jacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
Figure 202. Helicopter Jacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
Page i

Page ii
Section
071000
Lifting and Jacking
LIFTING AND JACKING

1. Lifting and Jacking A. Helicopter Hoisting
There is a requirement for jacking and leveling (Ref. Figure 201)
the MD Explorer, by means of hard points,
which are located on the airframe structure. Special Tools
(Ref. CSPSPM)
Jacking is essential to leveling, weight and Item Nomenclature
balance, as well as maintenance tasks T901 Helicopter Sling
performed on the landing gear or undercar
riage.
The aft jack pads are detachable from the CAUTION Use caution when you attach
airframe and are fabricated from steel forging. the sling. Avoid scratches on the main rotor
The jack pad is 2.50 inches (6.35 cm) hub.
diameter with a 0.875 inch (2.222 cm) (1). Locate lifting eyes (2) on main rotor
diameter protrusion extending 1.5 inches (3.8 hub (1).
cm) beneath the disk.
(2). Attach helicopter sling (T901) (4) to the
The end of the protrusion is spherical for the main rotor hub (1) using pins (3).
purpose of interfacing with standard aircraft (3). Attach ring on helicopter sling (T901)
floor jack stands and load cells. The jack pad is (4) to crane or hoist.
held on the aircraft by means of a single,
Airframe structure damage can
centrally located threaded stud. A knurled CAUTION occur if stress panels are not in
collar located around the base of the jack pad
will provide a hand grip for tightening of the place before hoisting.
jack pad into the aircraft receivers. All (4). Ensure all stress panels are installed
receivers are designed and located in such a (Ref. Section 06-00-00).
way as to allow the jack pads to be installed at (5). Secure a line to the tailboom and have
random, into any of the three positions on the an assistant hold line to keep helicopter
aircraft. from swinging.
(6). Apply tension to helicopter sling (T901)
by slowly and smoothly actuating hoist
or crane.
Hoisting
(7). Raise helicopter to desired height.
Page 201
B. Component Hoisting
NOTES:
(Ref. Figure 201)
(1) Examine aircraft weight and balance record
The approximate weights for large components per current Rotorcraft Flight Manual
that may require hoisting are listed in (Ref. Section 01-00-00, Table 201) for
Approximate Hoisting Weights (Ref. current weight.
Table 201).
Table 201. Approximate Hoisting Weights
Component Weight Lb (Kg)
Complete Helicopter 3350 (1520 Kg)
Blades 200 (91 Kg)
Empennage Assembly 69 (32 Kg)
Engine Complete (without oil) 285 (130 Kg)
Main Rotor Hub Assembly 160 (73 Kg)
Main Transmission 215 (98 Kg)
Tailboom (with bumper) 70 (32 Kg)
Thruster 29 (13 Kg)
3
4
1 2
(5 PL)
9G07-002A
1. MAIN ROTOR HUB 3. PINS

2. LIFTING EYES 4. HELICOPTER SLING (T901)
Figure 201. Helicopter Hoisting
Page 202
C. Helicopter Jacking NOTE: Use of the forward jack pad grease plate
allows the jack to adjust to the change in the
(Ref. Figure 202) longitudinal dimension. Use of the grease
plate is only required if you intend to change
the attitude of the aircraft.
Consumable Materials
Oil, Lubricating (C106)
(Ref. CSPSPM)
Item Nomenclature
C106 Oil, Lubricating
(4). Using lubricating oil (C106) lubricate

between forward jack pad grease plates
Special Tools (T206).
(Ref. CSPSPM)
Item Nomenclature (5). This will allow forward jack pad grease
T201 Jack Pad Kit
plates (T206) to slide over each other
when under load.
T2011 Aft Jack Pad
T2012 Forward Jack Pad
(6). Install forward jack pad grease plate
(T206) under the forward jack (T202).
T202 Helicopter Jack
T206 Forward Jack Pad Grease Plate
(7). Place jacks (9) under forward pad
assembly (4) and jack pads (6).
(1). Locate forward pad assembly attach CAUTION occur if stress panels are not in
points (1) on left and right forward place before jacking.
saddle assemblies (3 and 2) and align to
forward pad assembly (4). (8). Ensure all stress panels are installed
(Ref. Section 06-00-00).
(2). Install pins (5) through forward pad Jacking
assembly (4) and forward pad assembly
attach points (1).
(3). Install jack pads (6) to receiving points

located on left and right aft saddle (9). Evenly raise helicopter to desired
assemblies (7 and 8). height.
Page 203
07-10-00 Original
8 9
1 1
5
REF. 8

3 2
AFT SADDLE ASSEMBLY

4 6 (2 PLACES)
VIEW LOOKING FORWARD
9G07-001A
1. FORWARD PAD ASSEMBLY ATTACH POINTS 6. JACK PADS
2. RIGHT FORWARD SADDLE ASSEMBLY 7. LEFT AFT SADDLE ASSEMBLY
3. LEFT FORWARD SADDLE ASSEMBLY 8. RIGHT AFT SADDLE ASSEMBLY
4. FORWARD PAD ASSEMBLY 9. JACKS (T202)
5. PIN
Figure 202. Helicopter Jacking
Page 204
Original 07-10-00
Chapter
LEVELING / WEIGHT AND

BALANCE
TABLE OF CONTENTS
08-10-00 Weight and Balance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A

1. Weight and Balance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
2. Center of Gravity Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
A. Prepare To Weigh Helicopter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
B. Weigh Helicopter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
Figure 201.Helicopter Jack Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
Figure 202.Sample Weight and Balance Report Form . . . . . . . . . . . . . . . . . . . . . . 204
Figure 203.Surplus and Missing Equipment Form . . . . . . . . . . . . . . . . . . . . . . . . . 205
Figure 204.Basic Weight and Balance Form . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
Figure 205.Sample Basic Weight Check List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
08-20-00 Leveling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A
1. Helicopter Leveling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
A. Plumb Bob Leveling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
Figure 201.Helicopter Leveling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
Page i

Page ii
Section
081000
Weight and Balance
WEIGHT AND BALANCE

1. Weight and Balance (2). Defuel helicopter (Ref. Section
12-00-00).
(Ref. Figure 204 and Figure 205)
(3). Check lubricant level at engine oil tank,
Helicopter modifications and removal or main rotor gear box sight gages, and
addition of systems or components, result in hydraulic fluid reservoir sight gages
changes to weight and balance. These changes (Ref. Section 12-00-00).
must be recorded on the Basic Weight and
Balance Form, refer to the Rotorcraft Flight (4). If necessary, add lubricant if indication
Manual (Ref. Section 01-00-00, Table 201). is less than full. Fluid weights are
listed in Servicing Materials (Ref.
The Basic Weight Check List is supplied with Section 12-00-00, Table 1).
each helicopter, as part of the Rotorcraft Flight
Manual. It lists standard or optional systems (5). Weigh helicopter indoors on a hard
and components installed on the helicopter by surface and free from wind.
serial number.
FOD
Weight and center of gravity changes made WARNING
between when you weigh the helicopter, must
be recorded in the weight and balance record. (6). Make sure helicopter has no tools or
This will prevent a possible bad effect on the unwanted materials.
helicopters flight properties. (7). Find the weight and longitudinal
Basic weight and center of gravity is found by (LONG)/lateral (LATR) moment arms
doing a weight of the helicopter without of all equipment on the helicopter when
persons and load. Basic weight does include you weigh it, that will not be part of the
unusable fuel, full fluids, lubricants and helicopter basic weight.
installed systems and components. (8). Record on Surplus and Missing Equip
The maximum gross weight of the helicopter is ment Form.
specified in the Rotorcraft Flight Manual (Ref. (9). Record the total weight, arms, and
Section 01-00-00, Table 201). moments on the Actual Weight and
Balance Form.
2. Center of Gravity Limits
(10). Find the weight and LONG/LATR
Center of gravity limits are shown in the moment arms of all equipment that will
Rotorcraft Flight Manual (Ref. Section be installed after the helicopter is
01-00-00, Table 201). weighed, and will be part of the
A. Prepare To Weigh Helicopter helicopter basic weight.
(Ref. Figure 202 and Figure 203) (11). Record on Surplus and Missing Equip
ment Form.
NOTE: Weigh helicopter without fuel.
(12). Record the total weight, arms, and
(1). Connect helicopter to electrical ground moments on the Actual Weight and
(Ref. Section 10-10-00). Balance Form.
Page 201
B. Weigh Helicopter (7). Level helicopter (Ref. Section

08-20-00).
(Ref. Figure 201)
(8). Drain fuel sump (Ref. Section
Special Tools 12-00-00).
(Ref. CSPSPM)
Item Nomenclature
T2011 Aft Jack Pad
NOTE: On some helicopters MDHI uses a spe
cial jack pad at FS154.0 and lateral -9.3.
T2012 Forward Jack Pad On other helicopters MDHI uses lateral 0.0.
T206 Forward Jack Pad Grease Plate
(9). Record indication from helicopter weigh
T204 Helicopter Weigh System system (T204).
(1). Install the two aft jack pad (T201-1) (10). Lower helicopter until the three
and forward jack pad (T201-2) (Ref. helicopter jack (T202) or load cells are
Section 07-10-00). clear of the two aft jack pad (T201-1)
and forward jack pad (T201-2).
(2). Put a helicopter jack (T202) on forward
jack pad grease plate (T206) below
forward jack pad (T201-2). (11). Make sure helicopter weigh system
(T204) has an indication of 0000.
(3). Put a helicopter jack (T202) below each
aft jack pad (T201-1).
(12). If helicopter weigh system (T204) does
(4). Install helicopter weigh system (T204) not have an indication of 0000, record
as follows: the indication and subtract the values
from the weight recorded in step (9).
(a). If you use platform scales, put a
platform scale below each helicopter
jack (T202). (13). Calculate helicopter weight and balance
from the recorded data.
(b). If you use load cells, attach a load
cell to the top of each helicopter jack
(T202). (14). If it is necessary to weigh the helicopter
again, do steps (5). thru (13). again.
(c). Connect the wires between the
indication unit and the platform (15). Disconnect the wires from between the
scales or load cells. indication unit and the platform scales
(5). Set helicopter weigh system (T204) ON or load cells.
and adjust to an indication of 0000.
(16). Remove the three helicopter jack (T202)
Jacking and forward jack pad grease plate
(T206) from below the helicopter.
(17). Remove the two aft jack pad (T201-1)

If you jack the helicopter with and forward jack pad (T201-2) (Ref.
CAUTION out all stress panels installed, Section 07-10-00).
structural damage can occur. Make sure all
stress panels are installed (Ref. Section (18). Remove platform scales from below
06-00-00). helicopter or load cells from the three
helicopter jack (T202).
(6). Jack helicopter (Ref. Section 07-10-00).
Page 202
60 80 100 120 140 160 180 200 220 240 260 280 300 320 340 360 380 400 420 440 460 480
60 60
40 40
20 20
20 20
40 40
60 60
220 220
200 200
180 180
160
140
120 120
100 100
WL 106
FLOOR 80 80
60 60
FWD JACK POINT AFT JACK POINTS

STA 154.1 STA 233.0
BL 0 BL -23.3 AND +23.3
60 80 100 120 140 160 180 200 220 240 260 280 300 320 340 360 380 400 420 440 460 480
9G08-001B
Figure 201. Helicopter Jack Points
Page 203
AIRCRAFT ACTUAL WEIGHT

Model MD900 Serial No. 900-000XX Reg. No. N92XXX Date 12/23/XX
Weighed by J. Doe
EMPTY FULL
FUEL X
OIL, ENGINE LH X
OIL, ENGINE RH X
OIL, TRANSMISSION X
HYDRAULIC FLUID X
60 80 100 120 140 160 180 200 220 240 260 280 300 320 340 360 380 400 420 440 460 480
5 0
220 220
200 200
180 180
160 160
140
120 120
WL 106
FLOOR 100 100
80 80
60 60
FWD JACK POINT AFT JACK POINT

STA 154.1 STA 233.0
BL 0.0 BL -23.3 AND +23.3 9g08009B
LONGITU LONGITU
AVE. SCALE TARE OR NET LATERAL LATERAL
DINAL DINAL
WEIGHING POINT READING CALIB. CORR. WEIGHT ARM MOMENT
ARM MOMENT
LBS LBS LBS IN IN-LBS
IN IN-LBS
Forward (NOTE 1) 869.7 0.0 869.7 154.1 0.0 133929 -8066
Aft Right 1289.5 0.0 1289.5 233.0 23.3 300454 29981
Aft Left 887.5 0.0 887.5 233.0 -23.3 206788 -20634
TOTAL (AS WEIGHED) 3046.7 210.4 0.4 641170 1280
Less : Surplus Weight (See Table 1) -1.8 189.4 -10.4 -346 19
Plus: Missing Required Equipment (See Table 1) 222.6 198.0 0.0 44071 0
TOTAL - BASIC WEIGHT 3267.4 209.6 0.4 684895 1299
NOTE 1: ON SOME HELICOPTERS MDHI USES A SPECIAL FORWARD JACK PAD AT FS 154.0 AND LATERAL 9.3. ON OTHER
HELICOPTERS MDHI USES LATERAL 0.0.
NOTE 2: IN LEVEL ATTITUDE, MAIN ROTOR MAST IS TILTED 5 DEGREES FORWARD.
Figure 202. Sample Weight and Balance Report Form
Page 204
Form HOQ015 (Rev 5/00) MD Helicopters, Inc.
9G08-003A
Figure 203. Surplus and Missing Equipment Form
Page 205
08-10-00 Revision 7
Form HOQ014 (Rev (5/00) MD Helicopters, Inc.
9G08-004A
Figure 204. Basic Weight and Balance Form
Page 206
Revision 7 08-10-00
9G08008
Figure 205. Sample Basic Weight Check List
Page 207
Page 208
Section
082000
Leveling
LEVELING
1. Helicopter Leveling (2). Locate keyhole slot (2) in upper aft left
hand cabin door beam (4).
Provisions are made in the design for a
leveling target on the cabin floor, allowing for (3). Attach plumb bob line (5) to keyhole
leveling the helicopter with a plumb bob. A slot (2).
corresponding ceiling location for suspension of (4). Remove left cabin carpet (Ref. Section
a plumb bob relates to the floor leveling 25-20-00) from floor area (1).
marks.
(5). Locate unpainted rivet (3) for plumb
The target is a rivet head located under the bob (5) alignment.
carpet, near the aft left hand cabin door pillar.
CAUTION occur if stress panels are not in
A. Plumb Bob Leveling
place before jacking.
(Ref. Figure 201) (6). Ensure all stress panels are installed
Special Tools Jacking
(Ref. CSPSPM)
Item Nomenclature
T201 Jack Pad Kit
(7). Jack helicopter (Ref. Section 07-10-00).
T205 Plumb Bob
(8). Adjust jacks (T202) until plumb bob is
in alignment with the leveling target
(1). Remove closeout panel, covering upper (3) (rivet head). This ensures aircraft
aft left hand cabin door beam (4) (Ref. attitude is 0 degrees both longitudinally
Section 25-20-00). and laterally.
Page 201
08-20-00 Original
2 (NOTE 2)
FS 215.425
5 BL 26.757
WL 155.025
3
1 (NOTE)
NOTE: RIVET LOCATION: FS 215.425

BL 26.757
WL 105.953
9G08005
1. FLOOR AREA 4. UPPER AFT LEFT HAND CABIN DOOR BEAM
2. KEYHOLE SLOT 5. PLUMB BOB
3. RIVET
Figure 201. Helicopter Leveling
Page 202
Original 08-20-00
Chapter
TOWING
TABLE OF CONTENTS
09-00-00 Towing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A
1. Towing Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
A. Helicopter Manual Moving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
B. Helicopter Towing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
C. Helicopter Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
Figure 201. Helicopter Towing and Ground Handling . . . . . . . . . . . . . . . . . . . . . . . 203
Page i

Page ii
Section
090000
Towing
TOWING
1. Towing Requirements (3). Attach ground handling wheel set
(T101) (3) to attach points (2) on skid
The requirement to ground transport the MD tubes (1).
Explorer on prepared surfaces is met by means
of skid mounted ground handling wheels. (4). Hold tail up while lowering ground
handling wheel set (T101) (3).
The ground handling wheel set (3) consists of (5). Jack hydraulic ram, which forces
two each, dual wheel assemblies, which wheels down and skids up.
support a fully equipped MD Explorer approxi
mately three inches above the ground. (6). When the jack is extended, a mechani
cal safety latch automatically snaps
The ground handling wheel set (3) is used for into position, to prevent the wheels
moving the MD Explorer by hand and for from going up in the event of loss of
towing. The wheels are manually lowered with hydraulic pressure.
a detachable jack handle, and are held in the
Lead Lag Loads
down position by a mechanical lock. The CAUTION
ground handling wheel set is equipped with a
tow bar attach fitting. (7). Excessive lead-lag load applied to the
main rotor blades during ground
At regular intervals examine tire pressure and handling can result in damage to the
repack wheel bearings (Ref. Section damper assembly.
32-40-00).
A. Helicopter Manual Moving
place before moving helicopter.
(Ref. Figure 201)
(8). Ensure all stress panels are installed
Special Tools
When ground handling helicop
(Ref. CSPSPM) CAUTION ter do not lift main rotor blades
Item Nomenclature
to clear objects. The main rotor should be ro
T101 Ground Handling Wheel Set tated to clear objects.
(9). Ensure cyclic stick is centered and do
NOTE: The ground handling wheel set (T101) not exceed the maximum up limits for
attaches at four points, two inboard and two the main rotor hub flexbeam during
outboard, on the skid assemblies. ground handling, maintenance and
pre-flight operations.
(1). A handle assembly is strapped to the
Do not move the rotor blade tip
skid tubes and extends out, to pull the CAUTION up more than 4.0 ft. (1.22 m)
wheels to and from the helicopter.
when the rotor is not in operation. And do
not move the flexbeam up more than 1.0 in.
(2). Position ground handling wheel set (2.54 cm) at the blade attach point. Dam
(T101) (3) over skid tubes (1) and roll age to the flexbeam can occur.
ground handling wheel set (3) forward.
(10). Manually move helicopter on ground
NOTE: The wheel set can be installed in either handling wheel set (3) by balancing
direction, depending on jack handle posi tailboom and pushing on rear fuselage
tion. portion of airframe.
Page 201
09-00-00 Original
B. Helicopter Towing Do not move the rotor blade tip

CAUTION up more than 4.0 ft. (1.22 m)
(Ref. Figure 201) when the rotor is not in operation. And do
(2.54 cm) at the blade attach point. Dam
Special Tools
age to the flexbeam can occur.
(Ref. CSPSPM)
Item Nomenclature (8). Avoid short turns, which could cause
T101 Ground Handling Wheel Set helicopter to turn over.
T102 Tow Bar A safe minimum turning radius
CAUTION is approximately 20 feet.
The towbar (5) is equipped with caster wheels (9). Allow inside wheel to turn (not pivot)
and is designed for use with the ground while helicopter is being turned.
handling wheel set (T101) (3) and allows the (10). Detach tow bar (T102) (5) from power
helicopter to be moved by one person. unit.
The towbar (5) does not interfere with equip (11). Release ratchet handles on tow bar (5),
ment that may be hung under the helicopter before ground handling wheel set
(T101) is lowered completely.
(1). Raise helicopter up with ground
(12). Detach nylon straps under skid tube
handling wheel set (T101) (3).
assembly (1).
(2). Position caster wheels on tow bar C. Helicopter Transport
(T102) (5) to straddle over front skid
tube assembly (1). (Ref. Figure 201)
(3). Attach nylon straps under skid tube Special Tools

assembly (1) and ratchet skid tube (Ref. CSPSPM)
assembly (1) into rubber cups, on tow Item Nomenclature
bar (T102) (5). T101 Ground Handling Wheel Set
T102 Tow Bar
(4). Attach tow bar (5) to a power unit.
T103 HeliPorter
CAUTION occur if stress panels are not in The heli-porter (T103) (4) is designed for the
place before towing helicopter. MD Explorer with the use of a towing tractor
or vehicle.
(5). Ensure all stress panels are installed
(Ref. Section 06-00-00). The heli-porter (T103) (4) is a welded tubular
steel frame with dual pneumatic swivel casters
Do not tow helicopter at speeds on the front and rear. The platform is a grated
CAUTION over 5 mph. walkway with hold down safety straps with
mechanical ratchet locking for the skid tube
(6). Avoid sudden stops and starts. landing gear. The heli-porter (4) has a hand
brake to the rear tires and has a 10,000 lb
When ground handling helicop (4540 Kg) capacity.
CAUTION ter do not lift main rotor blades
to clear objects. The main rotor should be ro (1). Land or hoist helicopter (Ref. Section
tated to clear objects. 07-10-00) on heli-porter platform (4).
(7). Ensure cyclic stick is centered and do CAUTION occur if stress panels are not in
not exceed the maximum up limits for place before towing helicopter.
the main rotor hub flexbeam during
ground handling, maintenance and (2). Ensure all stress panels are installed
pre-flight operations. (Ref. Section 06-00-00).
Page 202
Original 09-00-00
Do not move the rotor blade tip When ground handling helicop
CAUTION up more than 4.0 ft. (1.22 m) CAUTION ter do not lift main rotor blades
when the rotor is not in operation. And do to clear objects. The main rotor should be ro
not move the flexbeam up more than 1.0 in. tated to clear objects.
(3). Attach safety hold-down straps on not exceed the maximum up limits for
heli-porter (4) to skid tube assembly the main rotor hub flexbeam during
(1). ground handling, maintenance and
Do not tow helicopter at speeds pre-flight operations.
CAUTION over 5 mph. A safe minimum
turning radius is approximately 20 feet.
(6). Attach heli-porter (4) hook-up to a tow
(4). Release heli-porter (4) hand brake. vehicle.
5
1
VIEW ROTATED
3
2
4
VIEW ROTATED
9G09001A
1. SKID TUBE ASSEMBLY 4. HELIPORTER (T103)
2. GROUND HANDLING ATTACH POINTS 5. TOW BAR (T102)
3. GROUND HANDLING WHEEL SET (T101)
Figure 201. Helicopter Towing and Ground Handling

09-00-00 Original
Chapter
PARKING AND MOORING

TABLE OF CONTENTS
10-10-00 Parking and Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A

1. Helicopter Parking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
A. Normal Conditions - Helicopter Parking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
B. Turbulent Conditions - Helicopter Parking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
2. Ground Service Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
A. External Power Receptacle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
B. Fuel Filler Port . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
C. Grounding Jacks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
Figure 201. Ground Service Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
3. Helicopter Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
A. Environmental Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
4. Flyable Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
A. General Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
B. Preparation For Flyable Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
C. Maintenance During Flyable Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
5. Short Term Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
A. General Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
B. Maintenance During Short Term Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
6. Intermediate Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
A. General Storage Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
B. General Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
C. Preservation for Intermediate Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
D. Maintenance During Intermediate Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
Figure 202. Helicopter Blade Tiedowns and Covers . . . . . . . . . . . . . . . . . . . . . . . . . 206
10-20-00 Mooring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A
1. Mooring Helicopter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
A. High Wind Conditions - Helicopter Mooring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
2. Covers and Tiedowns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
A. Forward and Aft Mooring Tiedowns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
B. Blade Tiedowns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
C. Upper Deck Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
Figure 201. Helicopter Covers and Mooring Tiedowns . . . . . . . . . . . . . . . . . . . . . . . 203
D. NOTAR Boom Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
E. NOTAR Thruster Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
Page i

F. Pitot Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
G. Bubble Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
H. Rotor Hub Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
I. Engine Area Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
J. Blade Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
K. Blade Covers (Cold Weather) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
Figure 202. Helicopter Protective Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
10-30-00 Return To Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A
1. Return to Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
A. Flyable Storage Depreservation and Activation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
B. Short Term Storage Depreservation and Activation . . . . . . . . . . . . . . . . . . . . . . . . . 201
C. Intermediate Storage Depreservation and Activation . . . . . . . . . . . . . . . . . . . . . . . 202
Page ii
Section
101000
Parking and Storage
PARKING AND STORAGE

1. Helicopter Parking Tiedown rotor blades, whenever
CAUTION helicopter is parked, to prevent
Use the following procedures when parking the rotor damage from blade flapping as a result
MD Explorer for short intervals. of air turbulence from other aircraft or wind
gusts. The maximum blade tie down load is
A. Normal Conditions Helicopter Parking when the blade tip just begins to deflect
downward.
(Ref. Figure 202) (5). Secure main rotor blades with blade
tiedowns (1), if helicopter is parked in
Procedures for parking the MD Explorer in an area subject to turbulence (Ref.
normal conditions, are for winds up to 45 Section 10-20-00).
knots.
(6). Ensure all switches are in the OFF
Protective covers and tiedowns are furnished position and external power is discon
as loose equipment, and are used for parking nected.
the MD Explorer.
(7). Install engine area cover (4), pitot cover
(2) and upper deck cover (3) (Ref.
Special Tools Section 10-20-00).
(Ref. CSPSPM)
Item Nomenclature (8). Close and secure all doors, windows
and access panels (Ref. Section
T108 Blade Tiedown 06-00-00).
T2008 Engine Area Cover
(9). Statically ground helicopter (Ref.
T107 Pitot Cover Section 10-10-00).
T106 Upper Deck Cover
B. Turbulent Conditions Helicopter
T110 Grounding Strap
Parking
Procedures for parking the MD Explorer in
(1). Locate helicopter in an area where turbulent conditions are for winds in excess 45
blades have sufficient clearance. knots.
When ground handling helicop (1). Park helicopter into the prevailing wind
CAUTION ter do not lift main rotor blades and secure in accordance with normal
to clear objects. The main rotor should be ro parking conditions.
tated to clear objects.
Section 10-10-00).
not exceed the maximum up limits for 2. Ground Service Connections
the main rotor hub flexbeam during
ground handling, maintenance and Ground service connections are located on the
pre-flight operations. right hand side of the fuselage below and
forward the pilot's door.
(3). Position helicopter in desired parking
area by taxiing or towing helicopter A. External Power Receptacle
(Ref. Section 09-00-00). (Ref. Figure 201)
(4). Allow helicopter to rest on landing gear The ground power receptacle (3) is 28 volts
skid tubes. DC.
Page 201
10-10-00 Original
B. Fuel Filler Port necessary to perform ground run-ups,

motoring of engines, defueling and purging of
(Ref. Figure 201) fuel cells and similar elements, must be
considered.
The fuel filler port (4) is for servicing the
helicopter with fuel. Wet weather conditions promote corrosion, rot,
mildew and mold. Perform regular inspections
C. Grounding Jacks to prevent these deteriorating effects.
(Ref. Figure 201) (1). Inspect for rot, mildew and mold, keep
nonmetallic materials clean and dry
(1). Locate grounding jacks (1) on right side (Ref. CSP-SPM).
of fuselage, adjacent to the fuel filler
port (4) or just below the ground power (2). Inspect and treat for corrosion control
receptacle (3). (Ref.CSP-SPM).
(2). To ground helicopter, install clamp and (3). Maintain full fuel cell to reduce con
grounding stud (2) into grounding jack densation in the cell (Ref. Section
(1). 12-00-00).
(3). To remove ground from helicopter, CAUTION ter do not lift main rotor blades
remove grounding jack (1) from clamp to clear objects. The main rotor should be ro
and grounding stud (2). tated to clear objects.
not exceed the maximum up limits for
3 the main rotor hub flexbeam during
1
ground handling, maintenance and
4 pre-flight operations.
3
D
(5). Store helicopter in hangar, if space
UN HE
O
R R
E
allows.
G
4. Flyable Storage
Flyable storage will maintain a stored MD
Explorer in an operable condition. If daily use
2 9G10-003A is impractical, the following procedures will
1. GROUNDING JACK
2. CLAMP AND GROUNDING STUD (T110)
keep the helicopter in flyable condition. At
3. GROUND POWER RECEPTACLE regular intervals inspect helicopter. Date and
4. FUEL FILLER PORT type of storage must be recorded in helicopter
records.
Figure 201. Ground Service Connections
A. General Procedures
3. Helicopter Storage (1). Corrosion control depends on control of
The following provides procedures to place the moisture. One method is ventilation, to
MD Explorer in storage. allow circulation of dry air through the
helicopter. Use fans or blowers, when
Protective covers serve as shields to prevent available.
entry of blowing dust, water, freezing rain, FOD
snow and/or foreign objects into the helicopter WARNING
during ground storage.
(2). Ensure drain holes are free of debris
A. Environmental Conditions and kept open during storage period.
Existing environmental conditions and (3). Perform pre-flight inspection per
facilities must be taken into account when the current Rotorcraft Flight Manual
helicopter is placed in storage. Conditions (Ref. Section 01-00-00, Table 201).
Page 202
B. Preparation For Flyable Storage (h). Record date engine was placed in
flyable storage in helicopter records.
(Ref. Figure 202)
(3). Hydraulic System
Special Tools (a). Service hydraulic system, to prevent
(Ref. CSPSPM) contamination or degradation (Ref.
Item Nomenclature Section 29-00-00).
T2008 Engine Area Cover (4). Fuel System
T108 Blade Tiedown
(a). Drain water from fuel cell per
T107 Pitot Cover
current Rotorcraft Flight Manual
T106 Upper Deck Cover (Ref. Section 01-00-00, Table 201).
(b). Fill fuel cells to full capacity (Ref.
(1). Drive System Section 12-00-00).
(a). Service drive system to prevent (5). Airframe
contamination or degradation (Ref.
Section 12-00-00, Transmission and (a). Open window air vents. Position air
Rotor Drive System). vents downward.
Tiedown rotor blades, whenever
(2). Engines CAUTION helicopter is parked, to prevent
(a). Clean and preserve engines in rotor damage from blade flapping as a result
accordance to manufacturers Engine of air turbulence from other aircraft or wind
Manual (Ref. Section 01-00-00). gusts. The maximum blade tie down load is
when the blade tip just begins to deflect
(b). Service engines, to prevent contami downward.
nation or degradation (Ref. Section
12-00-00). (b). Secure main rotor blades with blade
tiedowns (1) (Ref. Section 10-20-00).
NOTE: Run-up can be omitted if helicopter
was recently operated. (c). Install pitot cover (2) and upper deck
cover (3) (Ref. Section 10-20-00).
(d). Close doors (Ref. Section 06-00-00).
place before run-up. (e). Statically ground helicopter (Ref.
Section 10-10-00).
(c). Ensure all stress panels are installed
(Ref. Section 06-00-00). C. Maintenance During Flyable Storage
(d). Perform engine run-up, at least once (1). Perform pre-flight inspection, at least
every five days per current Rotorcraft once every seven days per current
Flight Manual (Ref. Section Rotorcraft Flight Manual (Ref. Section
01-00-00, Table 201). 01-00-00, Table 201).
(e). After engine run-up, service all (2). Inspect helicopter and treat for corro
helicopter systems to prevent con sion control (Ref. CSP-SPM).
tamination or degradation (Ref. (3). Inspect static ground wires, blade
Section 12-00-00). tiedowns and mooring devices at
regular intervals.
(f). Operate engines until oil tempera
ture is in normal operating range (4). Inspect tiedowns immediately after
and battery is fully charged (Ref. winds exceeding 45 knots.
RFM).
(5). Enter type of storage and date helicop
(g). Install engine area cover (4) (Ref. ter was placed in storage, in helicopter
Section 10-20-00). records.
Page 203
5. Short Term Storage Oil, Preservation (C118)
Short term storage (1 to 45 days) is used to

store the helicopter up to 45 days with very
little attention during the storage period.
(a). Fill fuel cell to full capacity with
A. General Preparation preservation oil (C118).
(b). Remove preservation oil using
(Ref. Figure 202) defueling procedures (Ref. Section
12-00-00).
(7). Remove battery (Ref. Section
(Ref. CSPSPM) 96-10-00) and store in waxed paper
Item Nomenclature and a wood crate.
C118 Oil, Preservation (8). Clean battery compartment (Ref.

Section CSP-SPM).
FOD
WARNING
Special Tools
(Ref. CSPSPM) (9). Ensure drain holes are free of debris
Item Nomenclature and kept open during storage period.
T2008 Engine Area Cover (10). Install engine area cover (4), pitot cover
T107 Pitot Cover (2) and upper deck cover (3) (Ref.
T106 Upper Deck Cover Section 10-20-00).
T104 Aft Mooring Tiedowns (11). Secure helicopter with aft mooring
T105 Forward Mooring Tiedowns tiedowns (5) and forward mooring
tiedowns (6) (Ref. Section 10-20-00).
(1). Inspect for corrosion every 15 days, if Section 10-10-00).
humidity exceeds 40%. Inspect for
corrosion every 30 days, if humidity (13). Remove objects that are likely to strike
does not exceed 40%. helicopter during high wind conditions.
B. Maintenance During Short Term Storage
(2). If interior temperature of fuselage
exceeds 160 F (71 C) open all doors Do not renew short term stor
CAUTION age.
and vents.
If conditions change, so a helicopter prepared
(3). Service all systems (Ref. Section for short term storage must remain in storage
12-00-00). for a longer period of time, represerve the
helicopter in accordance with Intermediate
(4). Preserve all systems completely to Storage (Ref. Section 10-10-00).
prevent contamination or degradation. (1). Preserve engine in accordance with
manufacturers Engine Manual (Ref.
(5). Inspect fuel, oil and hydraulic lines Section 01-00-00).
periodically for leakage. None allowed.
6. Intermediate Storage
(6). If fuel cell will remain without fuel for a Intermediate storage (46 to 180 days) is the
period of more than seven days, the fuel type of storage used for helicopters that will be
cell must be treated with a thin coating inactive for more than 45 days, but not
of preservation oil. exceeding 180 days.
Page 204
Original 10-10-00
A. General Storage Procedures (1). Clean and preserve engine in accor

dance with manufacturers Engine
Prior to engine run-up refer to manufacturers Manual (Ref. Section 01-00-00).
Engine Manual (Ref. Section 01-00-00).
(2). Drain fuel cell (Ref. Section 12-00-00).
B. General Inspection
(1). Ensure all removed components are (3). Deleted.
preserved and stowed in the helicopter (4). Rotors and controls will be preserved in
or at a designated location. accordance with Servicing (Ref. Section
(2). Main rotor blades will be removed and 12-00-00).
placed in a storage container and stored
(5). Remove battery (Ref. Section
under cover, (Ref. Section 62-10-00).
96-10-00) and seal in airtight plastic.
(3). Ensure records of all removed or
disconnected components is entered in (6). Clean battery compartment (Ref.
helicopter records. CSP-SPM).
(4). Check fuel, oil and hydraulic lines for (7). Airframe
leakage.
(a). Open window air vents. Position air
(5). Service helicopter in accordance with vents downward.
Servicing (Ref. Section 12-00-00).
(b). Close and secure all cowlings, panels,
(6). Ensure all bolts, washers, nuts etc. covers and doors (Ref. Section
which are removed during disassembly, 06-00-00).
are coated with a light coat of corrosion
preventive (Ref. CSP-SPM). (c). Install pitot cover (2) and upper deck
(7). Record type and date of storage in
helicopter records. (d). Statically ground helicopter (Ref.
Section 10-10-00).
C. Preservation for Intermediate Storage
D. Maintenance During Intermediate
(Ref. Figure 202)
Storage
Special Tools (1). If condition changes so helicopter

(Ref. CSPSPM) prepared for intermediate storage must
Item Nomenclature remain in storage for a longer period of
T108 Blade Tiedown time, represerve helicopter.
T107 Pitot Cover (2). Inspect engine in accordance with
T106 Upper Deck Cover Engine Manual (Ref. Section
01-00-00).
Page 205
5
6
3 4 6
2
9G10-001
1. BLADE TIEDOWN (T108) 4. ENGINE AREA COVER (T2008)
2. PITOT COVER (T107) 5. AFT MOORING TIEDOWNS (T104)
3. UPPER DECK COVER (T106) 6. FORWARD MOORING TIEDOWNS (T105)
Figure 202. Helicopter Blade Tiedowns and Covers
Page 206
Original 10-10-00
Section
102000
Mooring
MOORING
1. Mooring Helicopter (3). Secure helicopter to ramp tiedowns
using aft mooring tiedowns (1) and
Protective covers and tiedowns are furnished forward mooring tiedowns (2).
as loose equipment, and are used for mooring
the helicopter. (4). If a paved ramp with tiedown rings are
not available, park helicopter (Ref.
Section 10-10-00), on an unpaved
Special Tools parking area, headed in the direction
(Ref. CSPSPM) from which highest forecast winds are
Item Nomenclature expected.
T104 Aft Mooring Tiedowns
(5). Secure helicopter using aft mooring
T105 Forward Mooring Tiedowns
tiedowns (1) and forward mooring
T2008 Engine Area Cover tiedowns (2).
T107 Pitot Cover
Tiedown rotor blades, whenever
A. High Wind Conditions Helicopter rotor damage from blade flapping as a result
Mooring of air turbulence from other aircraft or wind
(Ref. Figure 201) when the blade tip just begins to deflect
downward.
When severe storm conditions or wind
velocities higher than 75 knots are forecast, (6). Remove main rotor blades, if possible
helicopter should be hangared or evacuated to (Ref. Section 62-10-00).
a safe area. If the helicopter must be parked in
the open during high winds, comply with the (7). Fill fuel cell, if possible (Ref. Section
following. 12-00-00).
Structural damage can occur (8). Install engine area cover (3), pitot cover
CAUTION from flying objects during high (4), (Ref. Section 10-00-00).
wind conditions. Helicopter should be han (9). Ensure all switches are in the OFF
gared or evacuated to a safe weather area position and external power is discon
when wind conditions above 75 knots are nected.
expected.
(10). Close and secure all doors, windows
(1). If a paved ramp with tiedown rings is and access panels (Ref. Section
available, park helicopter (Ref. Section 06-00-00).
10-10-00), on landing gear skids,
headed in direction from which highest (11). After winds subside, inspect helicopter
forecast winds are expected. carefully for damage which may have
been inflicted by flying objects.
CAUTION ter do not lift main rotor blades 2. Covers and Tiedowns
to clear objects. The main rotor should be ro
tated to clear objects. A requirement exists to shield the MD
Explorer from inclement weather conditions
(2). Ensure cyclic stick is centered and do and other outside environmental factors, that
not exceed the maximum up limits for could cause FOD damage during parking,
the main rotor hub flexbeam during mooring and storage. The covers described are
ground handling, maintenance and weather resistant, light weight and conform to
pre-flight operations. the helicopter contours.
Page 201
10-20-00 Original
A. Forward and Aft Mooring Tiedowns Tiedown rotor blades, whenever

(Ref. Figure 201) rotor damage from blade flapping as a result
of air turbulence from other aircraft or wind
Special Tools when the blade tip just begins to deflect
(Ref. CSPSPM) downward.
Item Nomenclature
Blade tiedowns (5) are socks, which fit over the
T104 Aft Mooring Tiedowns blade tip, with or without the blade covers
T105 Forward Mooring Tiedowns installed. Each blade tiedown is made of heavy
nylon and weighs approximately two pounds
(0.9 kg) each.
Forward and aft mooring tiedowns will be
supplied with the MD Explorer. Each tiedown Each blade tiedown (5), is fitted with a
will have a quick connect fitting with a generous length of rope which can be tied
streamer attached REMOVE BEFORE down at any convenient spot.
FLIGHT. C. Upper Deck Cover
(1). Two aft mooring tiedown straps (1) will (Ref. Figure 201)
come off the aft fitting.
Special Tools
(2). Two separate forward mooring tie (Ref. CSPSPM)
downs (2) attach to the forward fuse Item Nomenclature
lage. T106 Upper Deck Cover
(3). Attach forward mooring tiedowns (2) to

attach points on left and right side of The upper deck cover (6), encloses the NO
helicopter. TAR inlet, particle separator inlets and
exhaust stacks.
(4). Attach aft mooring tiedowns (1) to The upper deck cover (6) is reinforced in the
attach point on tailboom of helicopter. exhaust stack area to prevent burning. The
cover is made of heavy weight nylon and
B. Blade Tiedowns weighs approximately five pounds (2 kg).
(Ref. Figure 201) (1). Attach upper deck cover (6), at forward
corners to snap-head screws placed in
existing screw holes on lower edge of
Special Tools particle separator inlet.
(Ref. CSPSPM)
Item Nomenclature
(2). Attach upper deck cover (6), at rear
corners with similar snaps, or with a
T108 Blade Tiedown strap going underneath the tailboom
where it meets the fuselage.
Page 202
Original 10-20-00
1
2
3 2
6
9G10004
1. AFT MOORING TIEDOWNS (T104) 4. PITOT COVER (T107)
2. FORWARD MOORING TIEDOWNS (T105) 5. BLADE TIEDOWN (T108)
3. ENGINE AREA COVER (T2008) 6. UPPER DECK COVER (T106)
Figure 201. Helicopter Covers and Mooring Tiedowns
D. NOTAR Boom Cover E. NOTAR Thruster Cover
(Ref. Figure 202)
(Ref. Figure 202)
Special Tools
(Ref. CSPSPM)
Special Tools Item Nomenclature
(Ref. CSPSPM)
Item Nomenclature T2010 NOTAR Thruster Cover
T2009 NOTAR Boom Cover

The MD Explorer thruster cover (2) encloses
the thruster cone and chokes tightly around
the base near the trailing edge of the horizon
The MD Explorer boom cover (1) is a tubular tal stabilizor. The cover is made of medium
cover made of nylon. The cover weighs weight nylon and weighs approximately one
approximately five pounds (2 kg). pound (.454 kg).
(1). Position cover (2) on thruster.
(1). Attach boom cover (1) to thruster using
side-release buckles. (2). Tighten cover (2) with strap assembly.
Page 203
10-20-00 Original
F. Pitot Cover (6). A large bright red pocket is sewn in the

cover (4), for the pitot tube.
(Ref. Figure 202)
H. Rotor Hub Cover

Special Tools
(Ref. CSPSPM)
Item Nomenclature (Ref. Figure 202)
T107 Pitot Cover
The MD Explorer pitot cover (3), is vinyl and Special Tools

reinforced with galvanized steel staples at (Ref. CSPSPM)
stress points. Item Nomenclature
T2007 Rotor Hub Cover

A bright red warning streamer, REMOVE
BEFORE FLIGHT attaches to the bottom
edge of the cover
The MD Explorer rotor hub cover (5) overlaps
(1). Attach pitot cover (3), with nylon snap with the blade covers and the engine area
fastener around pitot base. cover to insure complete protection for the
entire main rotor system. The cover is made of
G. Bubble Cover
heavy weight nylon and weighs approximately
(Ref. Figure 202) three pounds (1 kg).
Special Tools (1). Position cover (5) over top of rotor hub.
(Ref. CSPSPM)
Item Nomenclature
T109 Bubble Cover Canopy
(2). Attach cover (5) with buckles under
each blade.
The MD Explorer bubble cover (4), encloses

the entire canopy, including the windshield, (3). Tuck lower part of cover (5) into the
skylights, front and rear doors and windows. aperture beneath the rotor.
The bubble cover is a medium weight nylon
treated for ultraviolet resistance and anti-
static buildup. The cover weighs approximate I. Engine Area Cover
ly nine pounds (4 kg).
(1). The cover (4), attaches at four points. (Ref. Figure 202)
(2). The cover (4), is color-coded, with

swatches sewn in the corners, for ease Special Tools
of installation. Red = Left, Green = (Ref. CSPSPM)
Right. Item Nomenclature
(3). Attach upper rear corners to snap-head T2008 Engine Area Cover
screws placed in existing screw holes on
lower edge of particle separator inlet.
(4). Attach straps at lower rear corners to The MD Explorer engine area cover (6) is
rear struts. similar and does the same job as the upper
deck cover, except that it also encloses the
(5). Tighten special rope in top and bottom main rotor. The cover weighs approximately
hems, to insure against wind chaffing. five pounds (2 kg).
Page 204
Original 10-20-00
J. Blade Covers (2). Tighten covers (7) at blade root with

attached straps and buckles.
(Ref. Figure 202)
(3). The small opening at the blade tip
Special Tools bottom allows attachment of tiedown
(Ref. CSPSPM) ropes.
Item Nomenclature
K. Blade Covers (Cold Weather)
T2011 Blade Covers
(Ref. Figure 202)
The MD Explorer standard blade covers
(T2011) are cut full to avoid trim tab damage. Special Tools
A small opening at the tip of the cover allows (Ref. CSPSPM)
for air circulation and drainage. The covers are Item Nomenclature
of medium weight nylon and weigh approxi
mately eight pounds (3 kg). T2012 Blade Covers (Cold Weather)
(1). Blade covers (7) can be installed with or

without tiedowns, and tied down at any The MD Explorer cold weather blade covers (8)
convenient spot on the ground with the are similar to the standard blade covers, but
aid of a lightweight rope attached to are fitted with full length zippers and heater
the open end. hose boots near the blade root.
5 6 2
3 7
4
9G10002
1. NOTAR BOOM COVER (T2009) 5. ROTOR HUB COVER (T2007)
2. NOTAR THRUSTER COVER (T2010) 6. ENGINE AREA COVER (T2008)
3. PITOT COVER (T107) 7. BLADE COVERS (T2011)
4. BUBBLE COVER CANOPY (T109) 8. COLD WEATHER BLADE COVERS (T2012)
Figure 202. Helicopter Protective Covers

10-20-00 Original
Section
103000
Return To Service
RETURN TO SERVICE
1. Return to Service B. Short Term Storage Depreservation and
Activation
Perform the following tasks for depreservation
and activation to return the MD Explorer to Special Tools
service. (Ref. CSPSPM)
Item Nomenclature
T2008 Engine Area Cover
A. Flyable Storage Depreservation and T108 Blade Tiedown
Activation T107 Pitot Cover
Special Tools
(Ref. CSPSPM) (1). Remove protective covers (T2008, T107
Item Nomenclature and T106) stow in designated location.
T2008 Engine Area Cover (2). Open all doors and ventilate helicopter
T107 Pitot Cover
T106 Upper Deck Cover (3). Remove tiedowns (T108) and stow with
other covers.
T108 Blade Tiedown
(4). Service and connect battery (Ref.
Section 96-00-00).
(1). Remove protective covers (T2008, T107 (5). Clean main rotor assembly (Ref.
and T106) stow in designated location. CSP-SPM, Section 20-20-00).
(6). Check fuel system for presence of water
(2). Clean helicopter as necessary (Ref. and drain as necessary.
CSP-SPM, Section 20-20-00).
(7). Fill fuel cell as necessary with approved
fuel (Ref. Section 12-00-00).
(3). Open all doors and ventilate helicopter
(8). Clean and service hydraulic system in
accordance with (Ref. Section
29-00-00).
(4). Remove blade tiedowns (T108) and (9). Clean and depreserve engine in
stow with other covers. accordance with manufacturers Engine
Manual (Ref. Section 01-00-00).
(5). Clean and depreserve engine in (10). Clean helicopter as necessary (Ref.
accordance with manufacturers Engine Section 20-20-00).
Manual (Ref. Section 01-00-00).
(11). Ensure all removed components have
been reinstalled. Check helicopter
(6). Record date helicopter was prepared for records for components that have been
service in helicopter records. removed or disconnected. Check for
subsequent installation.
(7). Remove static ground wire installed for (12). Ensure systems have been properly
storage. depreserved and serviced before any
Page 201
system or component operational test is (7). Transmission oil and lubrication pump
performed, refer to appropriate ATA filter assembly are to be replaced for
Chapter. aircraft that have been in storage in
excess of a year without operation (Ref.
(13). Remove static ground wire installed for Section 63-21-00).
storage.
(8). Install main rotor blades (Ref. Section
(14). Record date helicopter was prepared for 62-10-00).
service in helicopter records.
(9). Check fuel system for presence of water
C. Intermediate Storage Depreservation and and drain as necessary.
Activation
(10). Fill fuel cell as necessary with approved
Special Tools fuel (Ref. Section 12-00-00).
(Ref. CSPSPM)
(11). Clean and service hydraulic system in
Item Nomenclature
accordance with (Ref. Section
T2008 Engine Area Cover 29-00-00).
T108 Blade Tiedown
T107 Pitot Cover
(12). Clean helicopter as necessary (Ref.
(13). Ensure all removed components have
been reinstalled. Check helicopter
(1). Remove engine area cover (T2008),
records for components that have been
pitot cover (T107) and upper deck cover
removed or disconnected. Check for
(T106). Stow in designated location.
subsequent installation.
(2). Open all doors and ventilate helicopter
(14). Ensure systems have been properly
depreserved and serviced before any
(3). Remove blade tiedowns (T108) and system or component operational test is
stow with other covers. performed, refer to appropriate ATA
Chapter.
(4). Remove battery from storage and
install serviceable battery (Ref. Section (15). Remove static ground wire installed for
96-10-00). storage.
(5). Clean main rotor assembly (Rev (16). Record date helicopter was prepared for
CSP-SPM,. Section 20-20-00). service in helicopter records.
(6). Clean and service hydraulic system in (17). Perform preflight check (Ref.
accordance with (Ref. Section CSP-900RFM-1 900 CONFIG or
29-00-00). CSP-902RFM-1 902 CONFIG).
Page 202
Revision 1 10-30-00
Chapter
PLACARDS AND
MARKINGS
TABLE OF CONTENTS
11-00-00 Placards and Markings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A

1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
2. Decals and Placard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
A. Decal and Placard Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
Figure 201. Exterior Decal Installation (Sheet 1 of 3) . . . . . . . . . . . . . . . . . . . . . . . 203
Figure 202. Cockpit Decal Installation (Sheet 1 of 2) . . . . . . . . . . . . . . . . . . . . . . . . 206
Figure 203. Cockpit and Cabin Door Exit Decals (Sheet 1 of 2)
(Part of Interior Trim Installation) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208
Figure 204. Cabin and Baggage Decal Installation (Sheet 1 of 2) . . . . . . . . . . . . . 210
Figure 205. Upper Deck Decal Installation (Sheet 1 of 2) . . . . . . . . . . . . . . . . . . . . 212
Figure 206. Hydraulic GSE Panel (Part of Hydraulic System Installation) . . . . 214
Figure 207. Main Rotor Pitch Case Decal (Part of Main Rotor Installation) . . . 214
Figure 208. Transmission and Drive Service Decal
(Part of Transmission and Drive System) . . . . . . . . . . . . . . . . . . . . . . . . 215
Figure 209. Heat / Defog System Decal Installation . . . . . . . . . . . . . . . . . . . . . . . . 216
Page i

Page ii
Section
110000
Placards and
Markings
PLACARDS AND MARKINGS

1. General Interior Trim Installation.
(Ref. Figure 203.)
(Ref. Figure 201 through Figure 209.)
Cabin and Baggage Compartment Decal
Installation:
Placards and markings common to Model 900 (Ref. Figure 204.)
helicopters are shown in the following illustra
tions. Nomenclatures correspond to those used Upper Deck Decal Installation:
in the Illustrated Parts List, (IPL) for each
decal part number, and the quantity required. (Ref. Figure 205.)
The following illustrations cover different Hydraulic System GSE Panel Decal: Part of
areas of decal placement on the helicopter: Hydraulic System Installation.
(Ref. Figure 206.)
Exterior Decal Installation:
Main Rotor Pitch Case Decal: Part of Main
Rotor Installation.
(Ref. Figure 201.)
(Ref. Figure 207.)
Cockpit Decal Installation: Transmission and Drive Service Decal: Part of

(Ref. Figure 208.)
(Ref. Figure 202.)
Heat / Defog System Decal Installation:
Cockpit and Cabin Door Exit Decals: Part of (Ref. Figure 209)
Page 201
2. Decals and Placard (3). Where a decal is applied over a skin lap
(one skin overlapping another), the
A. Decal and Placard Application decal must be cut so that it lies flat and
makes a positive bond.
(Ref. CSPSPM) Adhesive, Epoxy (C407)
Item Nomenclature
C407 Adhesive, Epoxy
C420 Solvent, Cleaning
Adhesive, Epoxy (C411)
Solvent, Cleaning (C420)
(4). Seal edges of all exterior decals with

epoxy adhesive (C407), and only those
(1). Apply decals by wiping the surface area exterior upper deck (engine compart
with cleaning solvent (C420) where ment and transmission area) decals
decal is to be applied. Separate backing with epoxy adhesive (C411). Edge
from decal and apply decal to cleaned sealing to be a minimum of 1/32 inch
wiped surface area, roll out all (0.8mm) and a maximum of 1/8 inch
wrinkles. (3mm) around perimeter of decal.
(2). Where a decal overlaps or covers drain (5). ``N Number length will change from
holes, access doors, etc., the decal must aircraft to aircraft. After determining
be cut out to provide proper draining or the centerline of the ``N Number, align
ease of opening or removing of doors, as shown with dimension from aft edge
plates, etc. of door.
Page 202
28 (NOTE 4) 20 (NOTE 1)
24 (NOTE 1)
25 10
9 (NOTE 1) 23 ( NOTE 4 ) (NOTE 1)
11
26 (NOTE 1)
4 (NOTE 2)
B A
C
C
B A
12
23 ( NOTES 4 AND 5 ) 19 1 7
(NOTE 1) 18 (NOTE 1) (NOTE 2)
2 23
(NOTE 1) 3 14 6 (NOTE 1)
(NOTE 3) (NOTES 1 AND 2)
23
15 17 (NOTE 1)
FS 13
295.095 FS
233.000 16 17
15
21
16 15 16
17 13 17
8 (NOTE 2)
5 (NOTE 1)
WL
147.000
FS
400.000 A-A
BL
22 (NOTE 1) 0.000
C-C
NOTES:
1. MINIMUM EXTERIOR DECAL INSTALLATION
2. LEFT HAND SHOWN, RIGHT HAND TYPICAL 14
14 (NOTE 1)
3. WITH FUEL SYSTEM RANGE EXTENDER INSTALLED (NOTE 1) 14
4. WITH SUPPLEMENTAL FUEL SYSTEM INSTALLED 14
(NOTE 1) (NOTE 1) 9G11-001-1E
5. ALTERNATE LOCATION B-B
Figure 201. Exterior Decal Installation (Sheet 1 of 3)
Page 203
THRU THRU
THRU THRU
1. FUEL FILL LOCATION
2. REGISTRATION NUMBER, 3. REGISTRATION NUMBER,

WHITE, RH WHITE, LH
4. MCDONNELL DOUGLAS LOGO
SAFELOCK
SAFELOCK
5. BATTERY ACCESS LOCATION OPEN

OPEN
KEY
key
LOCK
lock SLAM
SLAM
10. EXTERIOR COCKPIT

DOOR (RIGHT SIDE)
6. STATIC PORT
7. AVIONICS ACCESS
SAFELOCK
OPEN
key
lock
SLAM
9. NO PUSH INFORMATION
8. PUSH INFORMATION 11. EXTERIOR COCKPIT
DOOR (LEFT SIDE)
14. NO STEP INFORMATION

13. JACK PAD
12. 28 VDC LOCATION
9G11-001-2G
Page 204
MCD ON NELL
HELICO PTER SYSTEMS
MESA, AZ .
MO DEL NO .
SERIAL N O.
TYPE CERT NO .
PR OD CER T NO .
19. PLATE IDENTIFICATION

15. FUEL DRAIN 16. FUEL SHROUD DRAIN 17. COMMON DRAIN 18. FUEL DRAIN EXTERIOR, MDX, MISC
CONTROLS
CAUTION
DISCONNECT ELECTRICAL WIRING
BEFORE REMOVING BOOM
21. ELECTRICAL DISCONNECT 22. EXTERIOR DOOR

20. ENGINE OIL FILL CAUTION INSTRUCTION, BAGGAGE 23. GROUND SYMBOL
24. EXTERIOR CABIN DOOR 25. EXTERIOR CABIN DOOR 26. FUEL CAP DECAL
INSTRUCTION (RIGHT SIDE) INSTRUCTION (LEFT SIDE)
(ORIGINAL CONFIGURATION (ORIGINAL CONFIGURATION
LATCH MECHANISM) LATCH MECHANISM)
USEABLE CAP. 158.5 U.S. GALS.

WITH RANGE EXTENDER INSTALLED
27. RANGE EXTENDER
28. FUEL FILL LOCATION

24. EXTERIOR CABIN DOOR 25. EXTERIOR CABIN DOOR SUPPLEMENTAL FUEL SYSTEM
INSTRUCTION (RIGHT SIDE) INSTRUCTION (LEFT SIDE)
(NEW CONFIGURATION (NEW CONFIGURATION
LATCH MECHANISM) LATCH MECHANISM)
9G11-001-3
Page 205
B B
E
E
6
A 4
G
A
E-E
D G C
B-B
D C
5
2 1 14 15
D-D
11
12
13
0.25 IN.
3 10 ( 6.35 MM )
A-A 1.23 IN.
7 ( 31.24 MM )
WITH SUPPLEMENTAL FUEL
SYSTEM INSTALLED
9 G-G 9G11-002-1G
C-C
Figure 202. Cockpit Decal Installation (Sheet 1 of 2)
Page 206
1. REFERENCE-FLIGHT MANUAL 2. RADIO CALL NUMBER
3. INFORMATION-AIRCRAFT LIMITATIONS
4. OPERATION-ROTOR BRAKE 6. NO SMOKING / FASTEN SEAT BELTS
5. INSTRUCTION-STATIC LINE DRAIN
NO PASSENGERS OR CARGO PERMITTED IN MAIN CABIN UNTIL INSTALLATION OF INTERIOR

ARRANGEMENT APPROVED BY THE COGNIZANT AIRWORTHINESS AUTHORITY
7. MAIN CABIN DECAL
10. CYCLIC CENTERING
AUXILIARY FUEL SYSTEM

USE MAIN FUEL DOWN TOo
8. MD900 COCKPIT VNE CARD INFORMATION 700 LBS BEFORE SELECTING
9. OPERATIONS RECORD HOLDER AUX FUEL TRANSFER. DO NOT
USE AUX FUEL TRANSFER BELOW
MAIN FUEL OF 300 LBS.
11. INSTRUCTION - SUPPLEMENTAL

NO-GO GO FUEL TRANSFER
12. OPERATION - SUPPLEMENTAL 13. OPERATION - SUPPLEMENTAL 14. TAKEOFF LIGHT 15. TAKEOFF LIGHT
FUEL TRANSFER PUMP ON FUEL TRANSFER PUMP OFF INDICATOR NO-GO INDICATOR GO LABEL
LABEL
9G11-002-2E
Figure 202. Cockpit Decal Installation (Sheet 2 of 2)
Page 207
4
1
RIGHT SHOWN
LEFT OPPOSITE
COCKPIT DOOR FRAME 2

LOOKING OUTBOARD 3
RIGHT SIDE
1 2 3
. . .
PUSH FOR FRESH

PULL FOR RECIRC HANDLE POSITION
DOOR OPEN
4 5
. .
9G11-008-1A
(Part of Interior Trim Installation)
Page 208
6
3
7
4
.
EARLY CONFIGURATION
4
.
CURRENT CONFIGURATION
4
5
5
.
7
6 .
.
9G110082
(Part of Interior Trim Installation)
Page 209
A A B
B
C C
FS D
230.50
WL
106.00
FS A-A FS
155.50 155.50
4
FS
230.50
RBL LBL 2
19.99 19.99
FS
248.00
3 B-B
E-E FS
155.50 6 5 FS 5
5 130.50
3 .3
3.8
E E
5
(TOP OF DECAL)
5 5
.3
D-D
5 C-C 5 5
9G11-003-1B
Figure 204. Cabin and Baggage Decal Installation (Sheet 1 of 2)
Page 210
SEAT ATTACH CAUTION

ONLY ROTATING FAN BLADES
NO TIEDOWN INSPECTION ACCESS ONLY
1. ATTACHMENT-SEAT ONLY 2. CAUTION-INSPECTION PANEL
CAUTION
CAUTION DO NOT CONNECT OR
(GCU) VOLTAGE REGULATION DISCONNECT UNIT WHILE
CONSULT MAINTENANCE MANUAL GENERATOR IS IN MOTION
FOR PROPER ADJUSTMENT WITHOUT OPENING GCU AND
GENERATOR FIELD
3. CAUTION, VOLTAGE REGULATION CIRCUIT BREAKERS
4. CAUTION-ELECTRICAL CONNECT/DISCONNECT
WARNING FUEL ACCESS DOOR

THIS PANEL MUST BE SECURED WARNING
PRIOR TO JACKING, TOWING
REPLACE DOOR BEFORE FLIGHT
OR FLYING THE AIRCRAFT
AND JACKING AIRCRAFT
5. ACCESS PANEL
6. FUEL ACCESS DOOR
9G11-003-2
Figure 204. Cabin and Baggage Decal Installation (Sheet 2 of 2)
Page 211
A
A
B
1
C
C
B
WL
160.00
FS
155.50
B-B 6 (NOTE)
2 (NOTE) 8
1
1
A- A
FS
C-C 155.50
6 (NOTE) 7 (NOTE)
5
NOTE: LEFT HAND SHOWN, RIGHT HAND TYPICAL 9G11-004-1B
Figure 205. Upper Deck Decal Installation (Sheet 1 of 2)
Page 212
1. FLIGHT CONTROLS 2. NO STEP
SERVICE WITH OIL SERVICE WITH

PER MIL-L-23699 MOBIL SHC 626 OIL
3. TRANSMISSION OIL FILL 3. TRANSMISSION OIL FILL
(USED ON PN 900D1400004 (USED ON PN 900D1400006
AND900D1400005 TRANSMISSION)
TRANSMISSION)
THIS COVER RETAINS SPRING LOADED SERVICE DRIVE PLATE SPLINE AIRCRAFT MUST BE PROPERLY GROUNDED
DRIVE SHAFT. SEE MAINTENANCE AND BATTERY DISCONNECTED
MANUAL FOR REMOVAL PROCEDURE WITH GREASE CONFORMING TO PRIOR TO SERVICING
SYNTECH 3913-G1
4. CAUTION-SPRING LOADED DRIVE SHAFT 5. SERVICE DRIVE PLATE SPLINE 6. CAUTION-BATTERY DISCONNECT
HYDRAULIC SERVICING
WARNING FLUID: MIL-H-83282
MAX RATED SUPPLY
PRESSURE: 1000 PSI (6,895 kPa)
FAILURE TO PROPERLY INSTALL,ALIGN MAX FLOW RATE: 2.2 GPM (0.14 L/S)
AND TORQUE,FUEL,OIL AND AIR TUBES MAX RETURN PRESSURE: 60 PSI (414 kPa)
AND FITTINGS COULD RESULT IN AN
ENGINE FAILURE.REFER TO THE APPLI SEE FLIGHT MANUAL AND LOG BOOK
CABLE MANUAL FOR PROPER INSTAL
ATION AND TORQUE PROCEDURES FOR ADDITIONAL INFORMATION
8. HYDRAULIC SERVICING
7. DECAL
9G11-004-2B
Figure 205. Upper Deck Decal Installation (Sheet 2 of 2)
Page 213
MD HELICOPTERS INC. MD HELICOPTERS INC.
900H7801501103
9G11006A
Figure 206. Hydraulic GSE Panel (Part of Hydraulic System Installation)
9G11-007
Figure 207. Main Rotor Pitch Case Decal (Part of Main Rotor Installation)
Page 214
SERVICE CARRIER SPLINE

WITH GREASE CONFORMING
TO SYNTECH 3913G1
9G11-005
Figure 208. Transmission and Drive Service Decal (Part of Transmission and Drive System)
Page 215
1 2
3 LOOKING INBOARD
RIGHT SIDE OF COCKPIT
FOOT HEATER
COCKPIT HEAT/DEFOG
PULL FOR HEAT PULL FOR HEAT
2. FOOT HEAT 3 COCKPIT HEAT/DEFOG
1. CABIN HEAT
9G11-009
Figure 209. Heat / Defog System Decal Installation
Page 216
Chapter
SERVICING
TABLE OF CONTENTS
12-00-00 Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A
Description And Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1. Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Figure 1.Servicing Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Table 1.Servicing Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1. Environmental Control System (ECS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
A. Air-Conditioning (AC) Servicing Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
B. AC System Servicing (EARLY CONFIG) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
Figure 201.AC Compressor Servicing Ports (EARLY CONFIG) . . . . . . . . . . . . . . 202
C. R-134A AC System Servicing (CURRENT CONFIG) . . . . . . . . . . . . . . . . . . . . . . . 204
Figure 202.AC Servicing Ports (CURRENT CONFIG) . . . . . . . . . . . . . . . . . . . . . . 204
D. Drain the AC Compressor Reduction Gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
Figure 203.Compressor Reduction Gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
E. Fill the AC Compressor Reduction Gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
Figure 204.Ground Ports for Fuel Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208
2. Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208
A. Fuel System Servicing Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208
Figure 205.Gravity Fill Port for the Main Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . 209
B. Servicing of the Main Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209
Figure 206.Gravity Fill Port for the Supplemental Fuel Tank . . . . . . . . . . . . . . . 210
C. Servicing of the Supplemental Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210
3. Defuel the Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211
A. Defuel the Main Fuel Cell at the Gravity Fill Port . . . . . . . . . . . . . . . . . . . . . . . . . . 211
B. Defuel the Main Fuel Cell at the Sump Drain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211
C. Defuel the Supplemental Fuel Cell . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211
Figure 207.Hydraulic System Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212
4. Hydraulic System Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213
A. Service the Hydraulic System with Hand Pump (Optional) . . . . . . . . . . . . . . . . . . 213
B. Service the Hydraulic System with Ground Support Equipment (GSE) Cart . . 213
Figure 208.Servicing of the Landing Gear Damper . . . . . . . . . . . . . . . . . . . . . . . . . 215
5. Landing Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215
A. Fill the Landing Gear Damper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215
6. Transmission and Drive System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216
A. Main Transmission Oil Fill/Add . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216
Figure 209.Main Transmission Oil Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216
B. Drain the Main Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216
Page i

Figure 210.Fan Bearing Lubrication Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217
C. Fan Bearing Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217
D. Rotor Brake Master Cylinder Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218
Figure 211.Rotor Brake Master Cylinder Servicing . . . . . . . . . . . . . . . . . . . . . . . . . 218
E. Rotor Brake Caliper Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218
Figure 212.Rotor Brake Caliper Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218
7. Powerplant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219
A. Engine Oil System Draining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219
B. Engine Oil System Filling/Replenishing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219
Figure 213.Engine Oil Filler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220
C. Fuel Catch Can (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221
Figure 214.Fuel Catch Can . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221
D. Engine Compressor Wash (Desalination) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221
E. Engine Compressor Wash (Performance Recovery) . . . . . . . . . . . . . . . . . . . . . . . . . . 222
Figure 215.Engine Wash Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222
8. Rotorcraft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223
A. Operation in a Corrosive Environment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223
9. Windscreen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224
A. Windscreen Washer (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224
Figure 216.Windscreen Washer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224
Page ii
Section
120000
Servicing
SERVICING
1. Description The locations of servicing points are shown in
Figure 1.
(Ref. Figure 1)
The servicing materials and capacities are
shown in Table 1.
Instructions and information for complete
servicing of the rotorcraft are provided in this Refer to directive and related manufacturer
section. Servicing includes replenishment of publications (ref. Section 01-00-00) for
fuel, changing or replenishment of oil, and servicing requirements for the engine fuel and
other such maintenance functions. oil filters, and rotorcraft battery.
11
1
2
3 12
9
6
10
14
6
7
5
13
15 5
4
9G12-002E
1. ECS AIRCONDITIONER REFRIGERANT 9. TRANSMISSION & DRIVE SYSTEM MAIN
EARLY CONFIG SHOWN TRANSMISSION LUBRICATING OIL
2. ECS AIRCONDITIONER SYSTEM OIL 10. ROTOR BRAKE MASTER CYLINDER HYDRAULIC
3. ECS COMPRESSOR REDUCTION GEARBOX OIL FLUID
4. FUEL SYSTEM FUEL 11. POWERPLANT ENGINE LUBRICATING OIL
5. HYDRAULIC SYSTEM GSE PANEL 12. POWERPLANT ENGINE WASH SOLUTION
6. HYDRAULIC SYSTEM MANIFOLD/RESERVOIR 13. POWERPLANT FUEL CATCH CAN (PW206A/E ONLY)
HYDRAULIC FLUID 14. ROTOR BRAKE CALIPER SPRAY LUBE
7. HYDRAULIC SYSTEM OPTIONAL HAND PUMP 15. WINDSCREEN WASHER (OPTIONAL) RESERVOIR
RESERVOIR HYDRAULIC FLUID FLUID
8. LANDING GEAR DAMPER FLUID
Figure 1. Servicing Points
Page 1
Table 1. Servicing Materials

Servicing Material (1) Capacity
System Consumable
Item Component Item No. Description Specification US Metric
1 AirConditioning C806 Refrigerant, (2) 5.0 lb 2.3 kg

Refrigerant R12
EARLY CONFIG
C815 Refrigerant (2) 3.5 lb 1.6 kg
R134A
1 AirConditioning C815 Refrigerant (2) 2.5 lb 1.1 kg

Refrigerant R134A
CURRENT CONFIG
2 AirConditioning C116 Hermetic Oil, 4.5 5.5 140 160

System Oil 150CX (R12) Fluid Cubic
Ounces Centimeters
C117 Hermetic Oil, 4.5 5.5 140 160
RG20, RS20, Fluid Cubic
DHPR (R134A) Ounces Centimeters
3 Compressor C106 Lubricating Oil (3) 1.0 30

Reduction Gearbox Fluid Cubic
Oil Ounces Centimeters
Fuel System
4 Fuel C113 Aviation Turbine MILDTL5624 146.2 553.4 Liters

Fuel Gallons (4) (4)
JP4, JP5 158.5 600.0 Liters
Gallons (4) (5)
C114 Aviation Turbine ASTM D1655 (4) (5)
Fuel
+29.4 +111.3 Liters
Jet A, Jet A1
Gallons (6) (6)
Hydraulic System
5 Hydraulic Fluid C112 Hydraulic Fluid (7) 2.2 Quarts 2.1 Liters
6 Manifold/Reservoir C112 Hydraulic Fluid (7) 1.0 Pints 0.5 Liters

Hydraulic Fluid
7 Optional Hand Pump C112 Hydraulic Fluid (7) 1.2 Quarts 1.1 Liters
Reservoir Hydraulic
Fluid
Landing Gear
8 Damper Fluid C105 Hydraulic Fluid MILH5606 2.3 Fluid 70.0 Cubic
Ounces Centimeters
Page 2
Table 1. Servicing Materials (Cont.)

System Consumable
9 Main Transmission C106 (8) Lubrication Oil (3) (8) 10.0 9.5 Liters
Lubrication Oil Quarts
C122 (9) Lubrication Oil Mobil SHC 626 10.0 9.5 Liters
(9) Quarts
Rotor Brake
10 Hydraulic Fluid C112 Hydraulic Fluid (7) 1.2 Pints 0.6 Liters
14 Rotor Brake Caliper C120 Spray Lubricant N/A As As

Required Required
Powerplant
11 Engine Lubrication (10) Lubrication Oil (2) (11) 1.3 Gallons 5.1 Liters
Oil (11)
12 Engine Wash (2) Cleaning Solution (3) (3) (3)

Solution
13 Fuel Catch Can N/A (12) N/A N/A N/A
Page 3
Table 1. Servicing Materials (Cont.)

System Consumable
Windscreen
15 Windscreen Washer (2) Distilled or N/A 2 Quarts 1.9 Liters

Reservoir (Optional) Deionized water
(13) C419 Isopropyl Alcohol N/A 1 Quart 0.95 Liter
NOTES:
(1) For the applicable product manufacturer(s) CAUTIONs and WARNINGs (ref. CSPSPM).
(2) Applicable specification in accordance with related manufacturers publications.
(3) MILPRF23699 lubrication oil supercedes MILL23699 type oil.
(4) Usable fuel for main fuel cell only. Total main fuel cell capacity is approximately 2.5 gallons (9.5 liters)
more.
(5) With range extender installed on main fuel cell.
(6) (PostTB900030) Total additional fuel with supplemental fuel cell installed.
(7) MILPRF83282 hydraulic fluid supercedes MILH83282 type fluid.
(8) MILPRF23699 is used only in transmission assemblies 900D1400004 and 900D1400005. Do not blend
with other oils.
(9) MOBIL SHC 626 is used only in transmission assembly 900D1400006101. Do not blend with other oils.
(10) MDHI Rotorcraft Maintenance Manual Consumable Item No. Not Applicable (N/A).
(11) Do not mix oil brands or types.
(12) Drain fuel catch can (Pratt&Whitney 206A and 206E Only) (ref. Section 120000, Maintenance
Practices).
(13) Distilled or deionized water for operations above 32F (0C). Distilled or deionized water with a 50 percent,
by volume, mixture of isopropyl alcohol for operations equal to or below 32F (0C).
Page 4
SERVICING
1. Environmental Control System (ECS) (3). Before servicing, all grease, oil, or other
foreign material must be cleaned from
A. AirConditioning (AC) Servicing the exterior surfaces of components.
Precautions
(4). Do not let unwanted materials (dirt,
Failure to follow air-condi sand, contamination) or moisture get in
WARNING tioning system servicing the system.
precautions can result in injury to per (5). The receiver dehydrator must be
sonnel and/or damage to rotorcraft. replaced each time the AC system is
opened.
Failure to follow the servicing
CAUTION procedures can have an effect on B. AC System Servicing (EARLY CONFIG)
the rotorcraft warranty. (Ref. Figure 201)
Oil, Daphne Hermetic (R12) (C116)
(Ref. CSPSPM)
Item Nomenclature
C116 Oil, Daphne Hermetic (R12)
C806 Refrigerant, R12
Oil, Daphne Hermetic (R134A) (C117)
Special Tools
(Ref. CSPSPM)
Item Nomenclature
Do not mix daphne hermetic oil T701 Refrigerant Recovery and Recycling
CAUTION (C116) and daphne hermetic oil
Station
(C117). Damage to the system can occur.
T702 Electronic Leak Detector
Refrigerant, R12 (C806)
Make sure the personnel that
CAUTION maintain and service the air-
conditioning system have the necessary
education and experience. The system has
complex and specialized components that
Refrigerant, R-134A (C815) require specific knowledge.
Failure to comply with
CAUTION manufacturers recovery and re
cycling station servicing requirements and
management of refrigerants, can result in
Do not mix R12 refrigerant damage to the air-conditioning system.
CAUTION (C806) and R-134A refrigerant
(C815). Damage to the system can occur. NOTE: Obey all government and local regula
tions with you fill and evacuate the AC sys
(1). Make sure of the System R number tems with refrigerant substances.
before AC system servicing. (1). Remove Access Panel R210 (ref. Section
53-30-00).
(2). Always fill refrigerant vapor into
high-pressure (discharge) side of (2). Remove caps (1, 2) from service ports
system. (Schrader valve) on compressor.
Page 201
(6). Remove access panels L210 and R210

(ref. Section 53-30-00).
(7). Defuel the rotorcraft (ref. Procedure 3.).
(8). Remove access panels A235, AR250,
and AL250 to get access to the condens
er (ref. Section 53-20-00).
1
(9). Remove right aft station 230.00
bulkhead baggage compartment
interior trim panels to get access to the
AC tube assemblies (ref. Section
25-50-00).
2
(10). Examine evaporator, condenser,
compressor, receiver dehydrator and all
fittings and tube connections for leaks.
(11). Repair connections and components
with leaks.
(12). If there are no leaks, continue the AC
RIGHT ENGINE SHOWN system servicing.
9G12-007 Refrigerant oil must be the
1. LOW PRESSURE INLET LINE CAP (REF. IPL, 215000, CAUTION same type specified by the
FIG. 1)
manufacturer of the compressor. Failure to
2. HIGH PRESSURE OUT LINE CAP
use the correct refrigerant oil can cause
Figure 201. AC Compressor Servicing Ports damage to the compressor.
(EARLY CONFIG)
NOTE:
(3). Service the AC system with refrigerant Make sure of the System R number be
recovery and recycling station (T701) fore you fill the AC system. Do not mix re
(ref. the related manufacturer publica frigerants.
tions for recovery and recycling station If the servicing is because of a component
operation/instruction information). replacement (other than the compressor
or after a leak that may have resulted in
(4). Pull a vacuum of 29.50 to 29.90 inHg
oil leakage has been fixed), go to Step
(74.17 to 75.95 cmHg) vacuum for 30
(13).
minutes.
If the servicing is because a new or over
(a). Measure the quantity of oil removed. hauled compressor was installed, go to
Step (15).
(5). The AC system must be able to keep
and hold 29.20 to 29.90 inHg (74.17 to (13). Before you fill the AC system:
75.95 cmHg) of vacuum for 30
Oil, Daphne Hermetic (R12) (C116)
minutes without a noticeable change
in the vacuum indication after the
pump is turned OFF.
(a). If the AC system keeps a vacuum for

30 minutes, go to Step (12). (a). For a R12 refrigerant system, add
the quantity of refrigerant oil re
(b). If the AC system does not keep a moved in Step (4).(a). then add 2.0
vacuum for 30 minutes, go to Step to 3.0 oz (60 to 90 cc) of daphne
(6). hermetic oil (C116).
Page 202
NOTE: Do not add more than 5.5 oz (160 cc) Use only a qualified mechanic or
total. CAUTION pilot to start and operate the en
gines.
Oil, Daphne Hermetic (R134A) (C117)
(19). Start the right engine (ref. applicable
RFM).
Rotor Blades
(14). Operate the rotorcraft at ground idle

(ref. applicable RFM).
(a). For a R-134A refrigerant system, (20). Set the AC/VENT switch to COOL
add the quantity of refrigerant oil LOW position on the UTILITY PAN
removed in Step (4).(a). then add 2.0 EL.
to 3.0 oz (60 to 90 cc) of daphne
hermetic oil (C117). (a). If the AC compressor does not
operate, refer to the Fault Isolation
NOTE: Do not add more than 5.5 oz (160 cc) Troubleshooting Table 101 (ref.
total. Section 21-50-00).
(b). Go to Step (15). (b). A two-second time delay will occur

before the compressor and condenser
(15). Replace oil removed from system as fans operate.
measured in Step (4).(a).
(c). The evaporator fan must operate
NOTE: Do not add more than 5.5 oz (160 cc) immediately
total. (21). With the AC/VENT switch set to the
COOL LOW position and the right
Refrigerant, R12 (C806)
engine in operation at ground idle, do a
check for cool/cold air from the 10 AC
gasper assemblies.
(a). If there is cool/cold air, turn the
Refrigerant, R-134A (C815) AC/VENT switch to OFF and stop
the engine.
(22). Let the refrigerant in the AC high-
pressure and low-pressure subsystems
equalize.
(16). Accurately and carefully meter refriger (23). Disconnect refrigerant recovery and
ant through refrigerant recovery and recycling station (T701).
recycling station (T701).
(24). Install caps (1, 2) from service ports
(a). If the system uses R12, add 5.0 lb (Schrader valve) on compressor.
(2.3 kg) of R12 refrigerant (C806).
(25). If necessary, install Access Panel T155
(b). If the system used R-134A, add 3.5 (ref. Section 53-30-00).
lb (1.6 kg) of R-134A refrigerant (26). If necessary, install Access Panel L210
(C815). (ref. Section 53-30-00).
(17). Examine system for leaks with elec (27). Install Access Panel R210 (ref. Section
tronic leak detector (T702). 53-30-00).
(18). Repair leaking connection that can be (28). If necessary, install access panels A235,
tightened. Other repairs will require AR250, and AL250 (ref. Section
evacuation of the system. 53-20-00).
Page 203
(29). If necessary, install right aft station Make sure the personnel that
230.00 bulkhead baggage compartment CAUTION maintain and service the air-
interior trim panels (ref. Section conditioning system have the necessary
25-50-00). education and experience. The system has
complex and specialized components that
require specific knowledge.
C. R134A AC System Servicing (CURRENT
CONFIG) Failure to comply with
CAUTION manufacturers recovery and re
cycling station servicing requirements and
(Ref. Figure 202) management of refrigerants, can result in
damage to the air-conditioning system.
Consumable Materials NOTE: Obey all government and local regula
(Ref. CSPSPM) tions with you fill and evacuate the AC sys
Item Nomenclature tems with refrigerant substances.
C117 Oil, Daphne Hermetic (R134A) (1). Remove Access Panel L155 to get
access to the AC service ports (ref.
C815 Refrigerant, R134A
Section 53-30-00).
(2). Remove caps (1 and 2) from service
ports (Schrader valve) on inlet and
Special Tools outlet tubes.
(Ref. CSPSPM)
Item Nomenclature (3). Service air conditioning with a refriger
ant recovery and recycling station
T701 Refrigerant Recovery and Recycling (T701). Refer to related manufacturers'
Station publications for recovery and recycling
T702 Electronic Leak Detector station operation instruction information.
(4). Pull a vacuum of approximate 29.50 to
29.90 inHg of vacuum for 30 min
utes.
(a). Measure quantity of oil removed.
(5). The system must be able to maintain
and hold 29.20 to 29.90 inHg of
vacuum for 30 minutes without
noticeable change in vacuum reading
after pump has been turned off.
(a). If the AC system keeps a vacuum for
30 minutes, go to Step (11).
1
2 (b). If the AC system does not keep a
vacuum for 30 minutes, go to Step
(6).
CURRENT CONFIGURATION (6). Remove Access Panel L210 (ref. Section
53-30-00).
LEFT FORWARD TRANSMISSION DECK SHOWN
9G12-015
1. LOW PRESSURE INLET LINE CAP (REF. IPL, 215000, (7). Remove Access Panel T155 to get
FIG. 2) access to the evaporator (ref. Section
2. HIGH PRESSURE OUT LINE CAP 53-30-00).
Figure 202. AC Servicing Ports (CURRENT (8). Remove Access Panel R210 (ref. Section
CONFIG) 53-30-00).
Page 204
(9). Inspect evaporator, condensers, com Refrigerant, R-134A (C815)

pressor, receiver dehydrator and all
fittings and tube connections for leaks.
(10). Repair connections and components

with leaks. (14). Accurately and carefully meter refriger
ant through refrigerant recovery and
(11). If there are no leaks, continue the AC recycling station (T701).
system servicing. (a). Add 2.5 lb (1.1 kg) R-134A refriger
ant (C815) for a system requiring
Oil, Daphne Hermetic (R134A) (C117) R-134A.
(15). Inspect system for leaks with electronic
leak detector (T702).
(16). Repair leaking connection that can be
tightened. Other repairs will require
Refrigerant oil must be the evacuation of the system.
CAUTION same type specified by the Use only a qualified mechanic or
manufacturer of the compressor. Failure to CAUTION pilot to start and operate the en
use the correct refrigerant oil will cause gines.
damage to the compressor.
(17). Start the right engine (ref. applicable
NOTE: RFM).
Make sure of the System R number be Rotor Blades

fore you fill the system.
Do not mix refrigerants.
If charging system due to replacement of
a component other than the compressor (18). Operate the rotorcraft at ground idle.
or after a leak that may have resulted in (19). Set the AC/VENT switch to COOL
oil leakage has been fixed, go to Step (12). LOW position on the UTILITY PAN
EL.
If charging the air conditioning because a
new or overhauled compressor will be (a). If the AC compressor does not
installed, go to Step (13). operate, refer to the Fault Isolation
Troubleshooting Table 101 (ref.
(12). Before you fill the AC system: Section 21-50-00).
(b). A two-second time delay will occur
(a). Add the quantity of refrigerant oil before the compressor and condenser
removed in Step (4).(a). then add 2.0 fans operate.
to 3.0 oz (60 to 90 cc) of daphne
hermetic oil (C117). (c). The evaporator fan must operate
immediately
(b). Do not add more than 5.5 oz. (160 (20). With the AC/VENT switch set to the
cc) total. COOL LOW position and the right
engine in operation at ground idle, do a
(c). Go to Step (14). check for cool/cold air from the 10 AC
gasper assemblies.
(13). Replace oil evacuated from system as (a). If there is cool/cold air, turn the
measured in Step (4).(a). Do not add AC/VENT switch to OFF and stop
more than 5.5 oz (160 cc) total. the engine.
Page 205
(21). Let the refrigerant in the AC high- (24). If necessary, install Access Panel T155
pressure and low-pressure subsystems (ref. Section 53-30-00).
equalize.
(25). If necessary, install Access Panel L210
(22). Disconnect refrigerant recovery and
(26). Install Access Panel L155.
recycling station (T701).
(27). If necessary, install Access Panel R210
(23). Install caps (1, 2) from service ports
(Schrader valve) on inlet and outlet (28). If necessary, install Access Panel L155
tubes. (ref. Section 53-30-00).
Page 206
D. Drain the AC Compressor Reduction (5). Let lubricating oil (C106) drain into
Gearbox container.
(Ref. Figure 203) (6). Install new packing (7) on drain plug
(6).
Consumable Materials (7). Install drain plug (6) with packing (7)
(Ref. CSPSPM) in compressor (1).
Item Nomenclature
C702 Lockwire (8). Safety drain plug (6) with new lockwire
(C702).
(9). Close Access Panel R210 (ref. Section
06-00-00).
3 1
2 4 5 E. Fill the AC Compressor Reduction
Gearbox
(Ref. Figure 203)
(Ref. CSPSPM)
Item Nomenclature
C702 Lockwire
RIGHT ENGINE 6 (1). Open Access Panel R210 (ref. Section

INBOARD VIEW 7 9G12-006A 06-00-00).
1. COMPRESSOR (REF. IPL 215000, FIG. 3)
2. REDUCTION GEARBOX (2). Remove lockwire (C702) from filler plug
3. FILLER PLUG (3).
4. PACKING
5. SIGHT GLASS (3). Remove filler plug (3) and packing (4).
6. DRAIN PLUG
7. PACKING
(a). Discard packing (4).
Figure 203. Compressor Reduction Gearbox
(1). Open Access Panel R210 (ref. Section
06-00-00).
(2). Remove lockwire (C702) from drain
plug (6).
(4). Fill compressor (1) with lubricating oil
(3). Put a suitable container below drain (C106).
plug (6) to catch lubricating oil (C106).
(a). Monitor the quantity of oil at sight
Oil, Lubricating (C106) glass (5).
(5). Install new packing (4) on filler plug
(3).
(6). Install filler plug (3) and packing (4).
(4). Remove drain plug (6) and packing (7).
(7). Safety filler plug (3) with new lockwire
(a). Discard packing (7). (C702).
Page 207
1, 4, 5
6
2 1
9G12-018
1. MAIN FUEL CELL GROUND PORT 5. SUPPLEMENTARY FUEL CELL OPTIONAL GROUND
2. MAIN FUEL CELL GRAVITY FILL PORT PORT
3. SUPPLEMENTARY FUEL CELL GRAVITY FILL PORT 6. GROUNDING STRAP
4. SUPPLEMENTARY FUEL CELL GROUND PORT
Figure 204. Ground Ports for Fuel Servicing
2. Fuel (4). At least one fully-charged 50 lb (23
kg) CO2 fire extinguisher must be
A. Fuel System Servicing Precautions available near the work area.
Failure to follow fuel system (5). The fuel vehicle must be parked 20 feet
WARNING servicing precautions can (6 meters) minimum from the
result in injury to personnel and/or rotorcraft during the fuel operation.
damage to the rotorcraft.
(6). Ground the fuel vehicle if possible.
(1). Only approved personnel can fuel the
rotorcraft. (7). Ground the rotorcraft before the start
of the fuel system servicing (ref.
(2). Clothing that makes static electricity Figure 204).
cannot be used by personnel.
(8). All rotorcraft electrical power must be
(3). Open flames and smoking are not OFF, unless you receive other instruc
permitted in the refueling area. tions from MDHI.
Page 208
FUEL QUANTITY MARKS 146 - GAL
152 - GAL
156 - GAL
SLOT
4
9G12016
1. GRAVITY FILL PORT (REF. IPL, 280000, FIG. 1) 3. LANYARD

2. FILLER CAP 4. GROUND PORT
Figure 205. Gravity Fill Port for the Main Fuel Tank
B. Servicing of the Main Fuel Tank Do not fill the fuel tank if the
CAUTION lanyard is broken.
(Ref. Figure 205)
Obey all fuel system servic (3). Put lanyard (3) in the slot of the
WARNING ing precautions. adapter of filler cap (2).
NOTE: The main fuel tank is located below the NOTE: The lanyard must be correctly attached
cabin compartment floor. Its capacity is to make sure the check valve is fully open.
1014 lb (460 kg) (149.0 US gallons (564 li
ters)). Aviation Turbine Fuel
Fuel helicopter with correct fuel
CAUTION as soon as possible after landing
to prevent moisture condensation. Con
densation can have an effect on rotorcraft
performance. Keep the fuel nozzle free of un
CAUTION wanted material. Contamina
(1). Ground the fuel nozzle or fuel vehicle to tion can damage the fuel system and have
ground port (4) or another bare metal an effect on rotorcraft performance.
surface.
(2). Remove filler cap (2). (4). Slowly fill the main fuel tank.
NOTE: There is an optional locking fuel cap (5). Install filler cap (2).
that can be installed on the gravity fill port.
A key is necessary to lock or open the fuel (6). Remove the fuel nozzle and ground(s)
cap. from the rotorcraft.
Page 209
4 (OPTIONAL LOCATION)
3
9G12017
1. GRAVITY FILL PORT (REF. IPL, 281000, FIG. 1) 3. LANYARD

2. FILLER CAP 4. GROUND PORT
Figure 206. Gravity Fill Port for the Supplemental Fuel Tank
C. Servicing of the Supplemental Fuel Tank NOTE: There is an optional locking fuel cap
(Ref. Figure 206) A key is necessary to lock or open the fuel
Obey all fuel system servic cap.
WARNING ing precautions.
Aviation Turbine Fuel
NOTE: The supplemental fuel tank is located
below the baggage compartment floor. Its
capacity is 204 lb (92.53 kg) (30 US gal
lons (113.56 liters)).
Fuel helicopter with correct fuel Keep fuel nozzle free of all un
CAUTION CAUTION wanted material. Contamina
as soon as possible after landing
to prevent moisture condensation. Con tion can damage the fuel system and have
densation can have an effect on rotorcraft an effect on rotorcraft performance.
performance.
(3). Slowly fill the supplement fuel tank.
(1). Ground the fuel nozzle or fuel vehicle to
ground port (4) or another bare metal (4). Install filler cap (2).
surface.
(5). Remove the fuel nozzle and ground(s)
(2). Remove filler cap (2). from the rotorcraft.
Page 210
3. Defuel the Fuel System (b). Drain the remaining fuel at the sump
drain (ref. Procedure 3.B.).
NOTE: The main fuel tank system can be de
fueled at the gravity filler port or the sump (6). Remove the hose from gravity fill port.
drain. But the gravity filler port method
(7). Install filler cap (2).
cannot completely drain all of the fuel from
the main tank. The sump drain procedure (8). If the fuel cell is to stay empty for more
must be done after the gravity filler port than 5 days, do the fuel cell preserva
procedure to completely empty the fuel tion procedure (ref. Section 10-10-00).
tank.
B. Defuel the Main Fuel Cell at the Sump
A. Defuel the Main Fuel Cell at the Gravity Drain
Fill Port
Obey all fuel system servic
WARNING ing precautions.
Special Tools
(Ref. CSPSPM) NOTE: Two fuel sump drain valves are located
Item Nomenclature on the bottom centered on the sump plate.
The valves are spring-loaded, normally
T804 Fuel Suction Pump Kit
closed, poppet drain valves. The valves open
T8041 Fuel Suction Pump Hose Set by pushing the control cable internal plung
er attached to fuel drain valve.
Obey all fuel system servic (1). Make sure the rotorcraft is as level as
WARNING ing precautions. possible.
(1). Ground the rotorcraft (ref. Figure 204). (2). Open access panels B178 and R185 (ref.
Section 06-00-00).
(2). Remove filler cap (2).
(3). Place a suitable container under fuel
NOTE: There is an optional locking fuel cap drain valves.
A key is necessary to lock or open the fuel
cap.
(3). Put the lanyard in the slot provided in

the filler cap adapter.
(4). Push the buttons of fuel sump drain
(4). Put 1.375 inch (34.93 mm) fuel suction controls to drain the fuel.
pump hose set (T804-1) in the fuel cell
through gravity fill port (1). (5). Close access panels B178 and R185 (ref.
Section 06-00-00).
(6). If the fuel cell is to stay empty for more
than 5 days, do the fuel cell preserva
tion procedure (ref. Section 10-10-00).
C. Defuel the Supplemental Fuel Cell
The gravity filler port cannot
CAUTION completely drain all of the fuel
(1). Apply electrical power to the rotorcraft
from the main fuel tank.
(2). Actuate supplemental fuel transfer
(5). Drain the fuel with fuel suction pump pump until the supplemental fuel
kit (T804) or a fuel service truck with gauge indicates EMPTY (ref. Section
defueling capabilities. 96-00-00).
(a). Drain the fuel into a suitable storage (3). Remove electrical power (ref. Section
container. 96-00-00).
Page 211
Obey all fuel system servic (6). After all fuel has drained from supple
WARNING ing precautions. mental fuel tank, replace packing and
install plug.
(a). Torque plug (ref. CSP-SPM).
(7). Drain the main fuel tank (ref. proce

dures 3.A. or 3.B.).
(4). Place a suitable container under the
fuel sump drain outlet.
(8). If the fuel cell(s) are to stay empty for
(5). Remove drain plug located on underside more than 5 days, do the fuel cell
of boat tail tub at FS 243.632 and LBL preservation procedure (ref. Section
9.160. 10-10-00).
4
MINIMUM
OIL LEVEL
1
3
HAND PUMP
FLUID TEMP
FLUID TEMP -40C 95C
-40C 95C FULL
F
F U
6 FULL
U L
L L
L REFILL
R REFILL
R E
5 E F
F I EMPTY
I L
L L VIEW LOOKING DOWN
L EMPTY
MANIFOLD / RESERVOIR
EARLY CONFIG MANIFOLD / RESERVOIR
CURRENT CONFIG 9G12-005B
1. HAND PUMP FLUID LEVEL SIGHT GAUGE (REF. IPL, 4. PUMP HANDLE
290000, FIG. 4) 5. MANIFOLD/RESERVOIR FLUID LEVEL SIGHT GAUGE
2. HAND PUMP RESERVOIR COVER (REF. IPL, 290000, FIG. 2)
3. SELECTOR VALVE LEVER 6. MANIFOLD/RESERVOIR BLEED VALVE
Figure 207. Hydraulic System Servicing
Page 212
4. Hydraulic System Servicing (5). Close access panels L155 and R155 (ref.
Section 06-00-00).
A. Service the Hydraulic System with Hand
Pump (Optional) B. Service the Hydraulic System with
Ground Support Equipment (GSE) Cart
(Ref. Figure 207)
(Ref. Figure 207)
(Ref. CSPSPM) Consumable Materials
Item Nomenclature (Ref. CSPSPM)
Item Nomenclature
C112 Hydraulic Fluid
(1). Open access panels L155 and R155 (ref.

Section 06-00-00). Special Tools
(Ref. CSPSPM)
(2). Examine sight gages (5) of both
Item Nomenclature
manifolds/reservoirs for low hydraulic
system fluid levels. T2001 Hydraulic Mule
(3). Do a check of the fluid level in the hand

pump at the sight gauge (1). (1). Open access panels L155 and R155 (ref.
Section 06-00-00).
(4). If the fluid level is low, do these steps:
(2). Examine sight gages (5) of both
(a). Remove cover (2). manifolds/reservoirs for low hydraulic
system fluid levels.
Do not mix different specifica
CAUTION tion hydraulic fluids. Make sure (3). If the fluid level is low, do these steps:
only hydraulic fluid (C112) is used to service Hydraulic Fluid (C112)
the hydraulic systems for all rotorcraft op
erations in temperatures more than -40F
(-40C). Damage to the rotorcraft can occur.
Hydraulic Fluid (C112)
Do not mix different specifica
CAUTION tion hydraulic fluids. Make sure
only hydraulic fluid (C112) is used to service
the hydraulic systems for all rotorcraft op
erations in temperatures more than -40F
(b). Add hydraulic fluid (C112). (-40C). Damage to the rotorcraft can occur.
(c). Install cover (2). (a). Select on the GSE panel the applica
ble system (1 or 2) for servicing.
(d). Select the system for servicing with
the selector valve lever (3) on the (b). Connect the pressure line from
hand pump. hydraulic mule (T2001) to the
pressure port on panel.
(e). Disengage pump handle (4) from its
stowed position. (c). Remove the drain tube from the BL
port on the manifold/reservoir of the
(f). Turn pump handle (4) in the direc applicable system.
tion of the arrow (clockwise).
(d). Clamp a 9-foot (3-meter) approxi
NOTE: Servicing is complete when the hydrau mate length of flex tube to the BL
lic manifold fluid level sight gauges (5) are port.
at the correct level.
(e). Put the other end of the flex tube in a
(g). Stow pump handle (4). bucket.
Page 213
Carefully adjust the hydraulic NOTE: During the bleed of the hydraulic sys
CAUTION pressure. Damage to the rotor tem, make sure the hydraulic fluid (C112)
craft hydraulic system can occur. level does not go below the REFILL line of
the fluid level sight gauge on the manifold/
(f). Set the pressure of hydraulic mule reservoir.
(T2001) to 500 psig (3448 kPa)
maximum. (d). Reduce the system pressure to 50
psig (345 kPa).
Do not make full or sudden
CAUTION movements of the main rotor (e). Open manifold/reservoir bleed valve
flight controls with the external hydraulic (6).
power applied to rotorcraft. The main rotor
flexbeams cannot accommodate full control (f). Examine hydraulic fluid (C112)
excursions (combinations of full collective through the flex tubing at the BL
and full cyclic movements) without centrifu port.
gal force.
(g). Let hydraulic fluid (C112) flow until
(g). Apply pressure to the rotorcraft there are no air bubbles.
hydraulic system.
(h). Close bleed valve (6).
(h). Monitor the fluid level at sight gauge
(5) while cycling flight controls. (i). Loosen the hose connections at the
(i). After you get to the correct fluid pump pilot ports.
level, stop cycling the flight controls. (j). Examine the discharge hydraulic
(j). Stop the pressure at hydraulic mule fluid (C112) for air bubbles.
(T2001).
(k). Let hydraulic fluid (C112) flow until
(k). Stop hydraulic mule (T2001). there are no air bubbles.
(4). Bleed the hydraulic system: (l). Torque the hose connections.
(a). Connect hydraulic mule (T2001) (m). Stop the pressure from hydraulic
return line to return port on the mule (T2001).
same GSE panel to which the hy
draulic mule pressure line is con (n). Stop hydraulic mule (T2001).
nected.
(5). Disconnect hydraulic mule lines from
(b). Apply 500 psig (3448 kPa) to the GSE panel.
hydraulic system with hydraulic
mule (T2001). (6). Install panel port covers.
(c). Cycle all hydraulic actuators at least (7). Remove flex tubing from manifold BL
15 cycles as you simultaneously port fitting and reconnect drain tube.
turn the main rotor head five times
minimum in the direction of normal (8). Close access panels L155 and R155 (ref.
blade travel. Section 06-00-00).
Page 214
5 4
REF. 4
3
FULL
RED
GREEN
9G12-001A
1. DAMPER (REF. IPL, 320000, FIG. 2) 4. RESERVOIR LEVEL INDICATOR
2. FILL PORT 5. FIRST NOTCH
3. BLEED VALVE
Figure 208. Servicing of the Landing Gear Damper
5. Landing Gear Hydraulic Fluid (C105)
A. Fill the Landing Gear Damper
(Ref. Figure 208)
(3). Fill the reservoir of damper (1) with
Consumable Materials hydraulic fluid (C105) in reservoir.
(Ref. CSPSPM)
Item Nomenclature (4). Open bleed valve (3) slightly.
C105 Hydraulic Fluid (5). Let hydraulic fluid (C105) bleed out
until there are no air bubbles in the
flow.
Special Tools (6). Close bleed valve (3).
(Ref. CSPSPM)
Item Nomenclature (7). Continue to fill the reservoir with
hydraulic fluid (C105) until the reser
T111 Fluid Service Unit voir level indicator (4) shows completely
full (all green).
The damper (1) must be in the (8). Remove fluid service unit (T111) from
CAUTION vertical position. If the damper fill port (2).
is not in the correct position, servicing can
not be done correctly. (9). Install cap on fill port (2).
NOTE: It is not necessary to remove damper (1) (10). Open bleed valve (3) slightly.
from the rotorcraft for servicing. (11). Drain hydraulic fluid (C105) from bleed
valve (3) until the red of fluid level
(1). Remove the cap from fill port (2). indicator (4) reaches first notch (5).
(2). Attach hydraulic fluid service unit NOTE: The servicing of the damper is correct
(T111) of 50 psi (minimum) to fill port when reservoir level indicator (4) is green
(2). with a very thin wedge of red seen to first
notch (5).
NOTE: Use a standard 37 female flared fitting
to connect to fill port (2). (12). Close bleed valve (3).
Page 215
6. Transmission and Drive System Do not put too much oil in trans
CAUTION mission. A too full transmission
A. Main Transmission Oil Fill/Add can cause very high pressure fluctuations.
(Ref. Figure 209) Oil, Lubricating (C106)
(Ref. CSPSPM)
Item Nomenclature (3). Add the correct lubricating oil to
C106 Oil, Lubricating transmission.
C122 Oil, Lubricating (4). Examine the quantity of oil in the
transmission at sight gage (4).
NOTE: Keep oil level between ADD and 1/2
FULL.
(5). Close filler cap (3).
06-00-00).
3 B. Drain the Main Transmission
(Ref. Figure 209)
Special Tools
2 (Ref. CSPSPM)
Item Nomenclature
1
T307 HeliLock Drain Attachment

06-00-00).
(2). Remove the chip detector (ref. Section
63-20-00).
4
(3). Put open end of heli-lock drain attach
9G12-004 ment (T307) (1) in an applicable
1. HELILOCK DRAIN ATTACHMENT container.
2. CHIP DETECTOR HOUSING (REF. IPL, 633000, FIG.
1) Oil, Lubricating (C122)
3. FILLER CAP (REF. IPL, 620000, FIG. 2) Oil, Lubricating (C106)
4. SIGHT GAGE (REF. IPL, 633000, FIG. 1)
Figure 209. Main Transmission Oil Servicing
Add lubricating oil (C122) to (4). Install heli-lock drain attachment

CAUTION 900D1400006-101 transmis (T307) (1) in chip detector housing (2).
sions only. Do not add lubricating oil (C122)
to other transmissions, damage will occur. (5). After the oil drains, remove heli-lock
drain attachment (T307).
(1). Open Access Panel R210 (ref. Section (6). Install the chip detector (ref. Section
06-00-00). 63-20-00).
(2). Open filler cap (3). 06-00-00).
Page 216
SCREW
FAN BEARING WASHER
WASHER
WING NUT
GREASE TOOL
PART A
GREASE TOOL
PART B
GREASE FITTINGS
9G12-014
Figure 210. Fan Bearing Lubrication Tool
C. Fan Bearing Lubrication

CAUTION
(Ref. Figure 210)
Either part number 500N or 900R bear
ings can be installed.
Consumable Materials The 500N bearings use aircraft grease
(Ref. CSPSPM) (C107).
Item Nomenclature
The 900R bearings use grease (C104).
C104 Grease
C107 Grease, Aircraft NOTE: This procedure provides 100% grease fill.
During operation, unwanted grease will ex
trude past seals until the correct fill is gotten.
Special Tools Grease (C104)
(Ref. CSPSPM)
Item Nomenclature
T604 AntiTorque Bearing Grease Tool
Grease, Aircraft (C107)
(1). Remove bearings from either the fan
pitch control assembly or fan support
(2). Carefully remove both seals from (5). Purge bearing with grease (C104) or
bearing. aircraft grease (C107) until clean grease
protrudes from all four holes in Part A of
(3). Inspect seals for damage. grease tool.
(a). No damage permitted. (6). Remove anti-torque bearing grease tool
(T604).
(4). Install bearing between grease tool
Part A and Part B, with a 4-inch 10-24 (7). Hand rotate bearing to purge excess
threaded bolt, washers, and wing nut. grease.
Page 217
Make sure seals are serviceable. (4). Install filler cap (1).
CAUTION If new seals are required, seals
and bearings must come from the same ven (5). Close Access Panel R155 (ref. Section
dor. 06-00-00).
(8). Carefully install seals. E. Rotor Brake Caliper Servicing

(9). Reinstall bearing in either the fan pitch (Ref. Figure 212)
assembly or fan support (ref. Section
64-30-30).
D. Rotor Brake Master Cylinder Servicing (Ref. CSPSPM)
Item Nomenclature
(Ref. Figure 211)
C120 Lubricant, Spray
(Ref. CSPSPM)
Item Nomenclature LUBRICATE
2
LUBRICATE
9G12-011
1. FILLER CAP (REF. IPL 632200, FIG. 1) 9G12-012
2. SIGHT GLASS
Figure 212. Rotor Brake Caliper Servicing
Figure 211. Rotor Brake Master Cylinder
Servicing
(1). Open Access Panel L210 or R210 (ref.
(1). Open Access Panel R155 (ref. Section Section 06-00-00).
06-00-00). Lubricant, Spray (C120)
NOTE: The rotor brake reservoir is located on
the top forward deck.
(2). Remove filler cap (1).
Do not allow lubricant to con
Hydraulic Fluid (C112) CAUTION tact brake disk or brake pad.
(2). Lubricate areas shown in Figure 212
with spray lubricant (C120).
(3). Fill reservoir to top of sight glass (2) (3). Close Access Panel L210 or R210 (ref.
with hydraulic fluid (C112). Section 06-00-00).
Page 218
7. Powerplant NOTE: This task is typical for left and right en

gine.
A. Engine Oil System Draining
(1). Open oil dipstick hand hold TL218 or
TR218 (ref. Section 06-00-00).
(Ref. CSPSPM)
Item Nomenclature
C702 Lockwire
NOTE: This task is typical for the left or the

right engine.
CAUTION
(1). Open Access Panel L210 or R210 (ref.
Section 06-00-00). Do not mix different brands or types of oil,
their chemical structure may make them
Oil, Lubricating (C106) incompatible.
If different brands or types of oil become
mixed, drain entire oil system and refill
with new oil.
Record oil brand and type in the Rotor
(2). Remove lockwire and disconnect engine craft Log Book and the applicable engine
oil out hose from oil cooler heat ex log book.
changer.
NOTE:
(3). Place engine oil out hose end into
suitable container. Check oil level 10 minutes after engine
shutdown, to reduce the possibility of
(4). Engage the rotor brake (ref. applicable over-filling the oil tank.
RFM). Correct oil level is when observed level is
between MAX and MIN marks on the oil
Obey the starter limits (ref. ap
CAUTION plicable RFM). Damage to the
dipstick. Filling oil tank to MAX may re
sult in oil being vented overboard, caus
starter can occur. ing a buildup of carbon deposits on the
(5). Dry-motor the engine for 30 seconds tailboom and empennage. Should this oc
minimum (ref. applicable RFM). cur, monitor engine oil level without add
ing oil (unless oil level falls below MIN) to
(6). Connect engine oil out hose to oil cooler determine if the level stabilizes at some
heat exchanger. point between MAX and MIN. When this
level is determined, fill oil to and main
(a). Torque nut. tain that level.
(b). Safety with lockwire (C702). (2). Remove engine oil filler cap.
B. Engine Oil System Filling/Replenishing (3). Refill engine oil tank with lubricating
oil (C106).
(Ref. Figure 213)
(4). Install and lock engine oil filler cap.
(a). Place dipstick in gearbox.
(Ref. CSPSPM)
Item Nomenclature (b). Make sure dipstick off-set of cap is in
C106 Oil, Lubricating line with off-set hole of gearbox oil
filler tube.
Page 219
(d). Make sure the cap handle is in the

CAUTION lock position.
Make sure the oil filler cap is installed
correctly. Incorrect installation can cause
NOTE: The writing on the cap handle must be
toward the front of the engine (ref.
disengagement of cap locking lugs, incor
Figure 213, View A).
rect sealing, and oil loss, which will re
quire an engine shutdown. (5). Close oil dipstick hand hold TL218 or
If extra force is required to lock cap, it is TR218 (ref. Section 06-00-00).
not installed correctly. Remove and ins
tall cap again.
(c). Turn the cap handle to close and lock
the cap.
MAXIMUM ALLOWABLE
OIL LEVEL
MINUMUM ALLOWABLE
OIL LEVEL
2
WRITING ON TAB FACING FORWARD
OIL FILLER DIPSTICK

(VIEW ROTATED)
MINIMUM OIL LEVEL

OIL LEVEL SIGHT GLASS
CHIP
DETECTOR
OIL FILTER
IMPENDING
VIEW LOOKING AFT BYPASS INDICATOR
NOTE: SOME ENGINE DETAIL OMITTED FOR CLARITY

9G12_009A
1. OIL LEVEL FILLER CAP 2. OIL FILLER HOUSING

Figure 213. Engine Oil Filler
Page 220
C. Fuel Catch Can (Optional) D. Engine Compressor Wash (Desalination)
Special Tools
(Ref. CSPSPM)
LEFT SIDE SHOWN
Item Nomenclature
VIEW LOOKING INBOARD T406 Compressor Wash Rig
T4061 Adapter
NOTE:
At or above 365F (25C) use drinking qual
ity water for desalination wash.
Below 365F (25C) use rinsing solution
1 (ref. P&WC Maintenance Manual, Direc
tives and Related Manufacturer Publica
tions, Section 01-00-00).
Water source pressure must be 60 to 82
psi (414 to 565 kPa).
2 CAUTION
Use correct rinsing solution mixture.
9G12-010A
1. FUEL CATCH CAN (REF. IPL, 717000, FIG. 2)
Engine temperature must be below 65_C
2. CATCH CAN DRAIN VALVE (150_F).
Figure 214. Fuel Catch Can To prevent damage, turn off inlet particle
separator and heat/defog shutoff valves.
NOTE: (1). Fill compressor wash rig (T406) with

water or rinse solution.
Use the fuel catch can with PW206A or
PW206E engines only. (2). Pressurize tank to 60 to 82 psi (414 to
565 kPa).
Drain the left and right fuel catch cans
daily. (3). Open Access Panel R210 (ref. Section
Fuel draining from overboard drain tube 06-00-00).
is an indication that fuel catch can is full (4). Connect engine compressor wash rig
and should be drained immediately. (T406) to engine wash panel with
adapter (T406-1).
starter can occur.
(5). Dry-motor the engine (ref. applicable

(1). Place a suitable container below drain RFM).
valve (2). (a). When NG reaches 5%, inject cleaning
solution into engine inlet.
(2). Push drain valve (2) up to drain the
fuel. (b). Turn starter OFF after 30 seconds.
Page 221
(c). Close valve for water when NG

decreases to 5%. CAUTION
Use correct cleaning and rinsing solution
(d). If the water/methanol mixture was mixture.
used, motor the engine for 30 se
conds minimum to dry the engine Engine must be below 65_C (150_F).
and remove flammable fumes. To prevent damage, turn off inlet particle
separator and heat/defog shutoff valves.
(6). Disconnect adapter (T406-1) from
engine wash panel.
(7). Do the dry-motor procedure on the

other engine (ref. Step (5).).

06-00-00).

starter can occur.
(9). Operate engines at idle for one minute

minimum to dry the engines (ref.
applicable RFM).
VIEW LOOKING
E. Engine Compressor Wash (Performance INBOARD
FROM RIGHT SIDE
Recovery)
(Ref. Figure 215)
Special Tools
(Ref. CSPSPM) 9G12-003A
Item Nomenclature
Figure 215. Engine Wash Panel
T406 Compressor Wash Rig
T4061 Adapter (1). Fill compressor wash rig (T406) with
cleaning solution and water or rinse
solution.
NOTE: (2). Pressurize tanks to 60 to 82 psi (414
Prepare cleaning solution (ref. P&WC to 565 kPa).
Maintenance Manual, Directives and Re
lated Manufacturers' Publications, Sec (3). Open Access Panel R210 (ref. Section
tion 01-00-00). 06-00-00).
At or above 365F (25C) use drinking qual (4). Connect engine compressor wash rig
ity water for the rinse. (T406) to engine wash panel with
adapter (T406-1).
Below 365F (25C) use a rinse solution (ref.
P&WC Maintenance Manual, Directives Obey the starter limits (ref. ap
and Related Manufacturer Publications,
Section 01-00-00). starter can occur.
The cleaning and rinse solution pressure (5). Dry-motor the engine (ref. applicable
must be 60 to 82 psi (414 to 565 kPa). RFM).
Page 222
(6). When NG reaches 5%, inject cleaning (12). Do this procedure on the other engine.
solution into engine inlet.
(7). Turn starter OFF after 30 seconds. 06-00-00).
(8). Close valve for cleaning solution when Obey the starter limits (ref. ap
NG decreases to 5%.
starter can occur.
(9). Let the cleaning solution soak for 10
minutes. (14). Operate the engines at idle for at one
minute minimum to dry the engines
Obey the starter limits (ref. ap (ref. applicable RFM).
starter can occur. 8. Rotorcraft
(10). Dry-motor the engine (ref. applicable A. Operation in a Corrosive Environment
RFM).
NOTE: A corrosive environment is an atmo
(a). When NG reaches 5%, inject solution sphere with high levels of abrasive dust,
into engine inlet. acidic or high-mineral-content soils, agri
cultural agents, extreme temperatures, in
(b). Inject the remaining solution. dustrial air pollution, or salt water vapor.
(c). If the water/methanol mixture was (1). Do the Rotorcraft Rinse Procedure
used, motor the engine for 30 se every day (ref. CSP-SPM, Section
conds minimum to dry the engine 20-20-00).
and remove flammable fumes.
(2). Do the Rotorcraft Wash Procedure
(11). Disconnect adapter (T406-1) from the every 14 days (ref. CSP-SPM, Section
engine wash panel. 20-20-00).
Page 223
9. Windscreen (a). No cracks or leaks are permitted.

A. Windscreen Washer (Optional) (5). Fill bottle (2).
(Ref. Figure 216) (a). For operation in temperatures above
325F (05C), fill with deionized or
distilled water.
(Ref. CSPSPM) Alcohol, Isopropyl (C419)
Item Nomenclature
C419 Alcohol, Isopropyl
N/A Deionized or Distilled Water
(b). For operation in temperatures equal

(1). Open Access Panel N80 (ref. Section to or below 325F (05C), mix 50%, by
06-00-00). volume, isopropyl alcohol (C419) with
deionized or distilled water.
(2). Disconnect elastic cord (1) from bottle
(2). (6). Install tubing (3) thru cap of bottle (2).
(3). Remove bottle (2) from nose compart (7). Install bottle (2) with elastic cord (1) in
ment and tubing (3). nose compartment.
(4). Examine bottle (2) for cracks and (8). Close Access Panel N80 (ref. Section
indications of leakage. 06-00-00).
9G12-013A
1. ELASTIC CORD (REF. IPL 531000, FIG. 7) 3. TUBING

2. BOTTLE
Figure 216. Windscreen Washer
Page 224
Chapter
VIBRATION AND NOISE

ANALYSIS
TABLE OF CONTENTS
18-00-00 Vibration and Noise Analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A

1. Vibration Analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
A. Main Rotor Vibration Monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
B. NOTAR Anti-Torque System Vibration Monitoring . . . . . . . . . . . . . . . . . . . . . . . . 1
C. Transmission and Drive System Vibration Monitoring . . . . . . . . . . . . . . . . . . . . . . 1
D. Vibration Trend Monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Figure 1. Balance Monitoring System (BMS) IIDS Interface . . . . . . . . . . . . . . . . . 2
Fault Isolation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
1. Main Rotor System Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Table 101. Main Rotor System Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
2. Anti-Torque System Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
Table 102. Anti-Torque System Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
1. Main Rotor Track And Balance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
A. Installing Main Rotor Blade Tracking Targets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
Figure 201.Main Rotor Blade Tracking Target Installation . . . . . . . . . . . . . . . . . . 201
B. Main Rotor Ground Track Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
C. Main Rotor Hover Track Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
D. In Flight Rotor Tracking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
E. Pitch Change Link Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
Figure 202.Pitch Change Link Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
F. Main Rotor Blade Tab Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
Figure 203.Main Rotor Blade Tab Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
G. Main Rotor Balance (On Ground) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
H. Main Rotor Balance (In Flight) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
I. Pitch Case Weight Adjustment (Recommended Location) . . . . . . . . . . . . . . . . . . . . 205
J. Hub Weight Adjustment (Alternative Location) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
Figure 204.Main Rotor Balance Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
2. Anti-Torque Fan Assembly Balance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
A. Anti-Torque Fan Balance Using Balance Monitoring System (BMS) in IIDS . . 207
B. Anti-Torque Fan Balance Weight Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208
Table 201.Anti-Torque Fan Recommended Balance Weights . . . . . . . . . . . . . . . . 208
Figure 205.Anti-Torque Fan Balance Weight Adjustment . . . . . . . . . . . . . . . . . . 209
Page i

3. Main Rotor Autorotation RPM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210
A. Autorotation RPM Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210
Figure 206.Autorotation RPM Chart (Sheet 1 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . 211
Page ii
Section
180000
Vibration and Noise
Analysis
VIBRATION AND NOISE ANALYSIS

1. Vibration Analysis B. NOTAR AntiTorque System Vibration
Monitoring
Vibration analysis is accomplished using the
sensors installed on the NOTAR anti-torque (Ref. Figure 1)
fan and the main rotor mast base assemblies. Anti-torque fan failure modes that would be
These sensors provide vibration levels to the detected by the BMS include:
Balance Monitoring System (BMS) processor
integrated into the Integrated Instrument Deteriorating fan blade airfoil or loss of blade
Display System (IIDS). mass due to erosion.
BMS software in the IIDS records the vibra Loose blade attach bolts or other associated
tion data and provides recommended adjust hardware.
ments for correcting imbalance condition in Loss of a fan blade is not yet predictable but
both the main rotor and the anti-torque fan the fan support structure is designed to handle
assembly. the resulting out of balance condition. The
BMS will detect anti-torque fan `òut of
A. Main Rotor Vibration Monitoring balance conditions. Maintainers will use this
as an indication to correct fan balance reduc
(Ref. Figure 1) ing vibration to an acceptable level of (0.15
IPS or less). Attempts should be made to
Typical causes for main rotor vibrations are: balance the assembly to the optimal balance of
(0.05 IPS).
Mass Imbalance (weight distribution) caused
by normal wear of rotor system components or C. Transmission and Drive System Vibration
blade replacement. Monitoring
(Ref. Figure 1)
Aerodynamic Forces caused by slight
differences in rotor blade airfoil shapes, blade Future enhancements to the BMS will include
twist, or erosion. monitoring transmission and drive system
components and engines.
The main rotor vibration sensor provides a
vibration level signal to the IIDS. BMS D. Vibration Trend Monitoring
software in the IIDS uses this data to deter The critical components of the main rotor
mine if the main rotor vibration levels are out system and anti-torque system are designed
of tolerance. to be replaced `òn condition. Warning of
abnormal conditions in these components will
BMS software also provides recommended be provided by three indications:
changes to pitch case weights, blade tabs or
pitch change links to bring the main rotor (1). BMS vibration monitoring trends,
vibration levels within tolerance. These
recommendations are based on information (2). Normal periodic inspections,
stored in the IIDS related to blade tab (3). Perceptible unusual vibrations at the
position, main rotor blade hub weights pilot's station.
installed, and pitch case weights installed.
The BMS can be the most sensitive of these
Typically, the BMS will be able to provide indications giving a warning in advance of the
balance corrections that will bring the other detection methods. Typically the BMS
vibration levels into tolerance within two sensors will be able to detect changes in
flights if the starting vibration level is no vibrations before they become apparent to the
greater than 0.5 IPS (Inches Per Second). pilot.
Page 1
The BMS captures vibration data and stores it This information can be used by maintainers
in a log to use in detecting changes in vibra to isolate failed or failing components.
tion levels over a period of time (trending).
Vibration trend monitoring of the main rotor
and anti-torque systems can provide an early
warning of system component progressive
failures.
IIDS UNIT
BALANCE MONITORING
ROTOR VERTICAL ROTOR VERT VIB POWER
VIBRATION
SENSOR
ROTOR VERT VIB SIGNAL
ROTOR
AZIMUTH ROTOR AZIMUTH SIGNAL
SENSOR
ROTOR LATERAL ROTOR LAT VIB POWER

VIBRATION
SENSOR
ROTOR LAT VIB SIGNAL
NOTAR
AZIMUTH NOTAR AZIMUTH SIGNAL
SENSOR
NOTAR NOTAR VIBPOWER

VIBRATION
SENSOR NOTAR VIB SIGNAL
9G18-001A
Figure 1. Balance Monitoring System (BMS) IIDS Interface
Page 2

FAULT ISOLATION
1. Main Rotor System Troubleshooting Troubleshooting tables should be used with
Rotor Vibrations system schematics, electrical wiring diagrams,
WARNING serviceability checks and other detailed
procedures in this and other chapters of the
The following troubleshooting procedures are a manual.
brief summary of main rotor system faults,
which may be encountered (Ref. Table 101).
Table 101. Main Rotor System Troubleshooting
Fault Probable Cause Corrective Action Ref. Section
Unusual or excessive Main rotor blades damaged. Inspect blades. 621000
vibration.
Vertical or lateral vibration. Main rotor hub or hub Inspect main rotor hub 622000
components damaged. assembly.
Oneper revolution lateral Defective main rotor hub Replace defective main rotor 622000
beat in hover and cruise. damper. hub damper(s).
May also occur on ground
during warm up or shutdown.
Oneper revolution vertical Main rotor blades out of Track main rotor blades. 180000
beat. Beat may appear track.
throughout entire flight
regime, becoming more
pronounced at higher
airspeeds.
Autorotation rpm low. Blade pitch is too high Lengthen pitch links equally. 180000
(Pitch links are too short).
Autorotation rpm high. Blade pitch is too low Shorten pitch links equally. 180000
(Pitch links are too long).
Fiveper revolution or Worn pitch control bearings. Replace pitch links. 623000
mediumfrequency beat.
Lateral feedback (beat) in Rotor blades out of track. Track main rotor blades. 180000
cyclic control stick with no
longitudinal.
High frequency vibrations. Loose or defective Inspect and replace damaged 640000
component in Antitorque components.
System.
Erratic track and balance Incorrect azimuth to sensor Verify azimuth sensor gap. 623000
readings. gap.
Crossover rotor instability Cyclic control not centered at Perform flexbeam inspection. 622000
High vertical, roll or pitch low rotor speed.
vibration felt by the pilot Damaged flexbeam. Perform flexbeam inspection. 622000
which occurs between
35%40% Nr on startup or
shutdown.
Page 101
2. AntiTorque System Troubleshooting Troubleshooting tables should be used with

system schematics, electrical wiring diagrams,
The following troubleshooting procedures are a serviceability checks and other detailed
brief summary of anti-torque system faults, procedures in this and other chapters of the
which may be encountered (Ref. Table 102). manual.
Table 102. AntiTorque System Troubleshooting
Unusual, excessive or high Damaged fan blade, worn Inspect and replace damaged 643000
frequency vibration. bearings, damaged fan blade components.
tensiontorsion straps, or
missing balance studs.
Erratic balance readings. Incorrect azimuth to sensor Verify azimuth sensor gap. 643000
gap.
Page 102
Original 18-00-00

1. Main Rotor Track And Balance (1). Release rotor brake, refer to current
Rotorcraft Flight Manual (Ref. Section
A. Installing Main Rotor Blade Tracking 01-00-00, Table 201).
Targets
(2). Turn main rotor until swashplate
(Ref. Figure 201) interrupter (2) is positioned above
azimuth sensor (1).
Special Tools (3). Remove screw (3) from forward rotor
(Ref. CSPSPM) blade (4).
Item Nomenclature
T903 Main Rotor Blade Track and Balance Kit (4). Install blade tracking target (6) number
one on blade tip. Torque screw.
NOTE: Blade tracking targets must be (5). Repeat steps (3). and (4). to install
installed in the correct sequence. Blade blade tracking targets (6) numbered
number one is located above nose of helicop two, three, four and five on each rotor
ter when swashplate interrupter is above blade, in sequence opposite the direc
azimuth sensor. Blades number 2, 3, 4, and tion the rotor turns.
5 are numbered in sequence opposite the di
rection the rotor turns.
DIRECTION
ROTOR TURNS BLADE 3
BLADE 2
BLADE 4
BLADE 1
BLADE 5 2
TARGET INSTALLATION SEQUENCE LOCATOR 1
5
3 INBOARD VIEW OF TAB
6
9G18-003B
1. AZIMUTH SENSOR 4. ROTOR BLADE

2. INTERRUPTER 5. BLADE WEIGHT COVER
3. SCREW 6. TRACKING TARGET
Figure 201. Main Rotor Blade Tracking Target Installation
Page 201
B. Main Rotor Ground Track Adjustment C. Main Rotor Hover Track Adjustment
Rotor Vibrations Rotor Vibrations
WARNING WARNING
(1). Install main rotor blade tracking
targets. (1). Install main rotor blade tracking
targets.
(2). Start one engine, refer to current
Rotorcraft Flight Manual (Ref. Section (2). Start and hover aircraft, refer to
01-00-00, Table 201). current Rotorcraft Flight Manual (Ref.
(3). Set main rotor RPM to 65% NR. Section 01-00-00, Table 201).
(4). Press MENU on IIDS key panel (Ref. (3). Press MENU on IIDS key panel (Ref.
CSP-900RMM-3, Section 95-30-00). CSP-900RMM-3, Section 95-30-00).
(5). Use the key to select BALANCE
(4). Use the key to select BALANCE
MONITOR from first level menu and
press ENT.
press ENT.
(6). Use the key to select MAIN ROTOR
TRACK from second level menu and (5). Use the key to select MAIN ROTOR
press ENT. Display changes to: FLASH TRACK from second level menu and
STROBE BLD SPREAD <ON> press ENT. Display changes to: FLASH
STROBE BLD SPREAD <ON>
(7). Point strobe light at main rotor blade
tips and press trigger. Record vertical (6). Point strobe light at main rotor blade
position of each rotor blade tracking tip. tips and press trigger. Record vertical
NOTE: Move strobe light in a ``W'' pattern while position of each rotor blade tracking tip.
pointed at blade tip path in front of aircraft
to find reflective blade tracking targets. NOTE: Move strobe light in a ``W'' pattern while
(8). Calculate adjustments necessary to to find reflective blade tracking targets.
correct blade track. Track must be
within 1 in. (2.54cm). (7). Calculate adjustments necessary to
(9). Make pitch change link adjustment. correct blade track. Track must be
within 1 in. (2.54 cm).
(10). Repeat steps (2). thru (8). with main
rotor RPM set to 100% NR. (8). Make pitch change link adjustment.
Page 202
D. In Flight Rotor Tracking NOTE: To increase blade pitch turn pitch

change link barrel left (shorten). To de
Rotor Vibrations crease blade pitch turn barrel right (length
WARNING en). If you turn barrel one flat you will
change track approximately one inch.
NOTE: Do the main rotor autorotation RPM
procedure before you make adjustments for (2). Adjust pitch change link (1) as shown
infight track and balance. by BMS solutions.
Control Rod Thread Engage
(1). Install Main Rotor Blade Tracking WARNING ment
Targets.
(3). Make sure there is sufficient thread
(2). Fly aircraft, refer to current Rotorcraft engagement between rod end (2) and
Flight Manual (Ref. Section 01-00-00, barrel (4). Put lockwire in witness holes
Table 201). at each end of barrel (4). If lockwire
goes through witness hole, pitch change
(3). Press MENU on IIDS key panel (Ref. link is lengthened too much.
CSP-900RMM-3, Section 95-30-00).
(4). Hold barrel (4) and torque nuts (3) to
(4). Use the key to select BALANCE 900 in-lbs (101.7 Nm).
press ENT. (5). Safety pitch change link nuts with
lockwire (C702).
(5). Use the key to select MAIN ROTOR
TRACK from second level menu and
press ENT. Display changes to: FLASH
STROBE BLD SPREAD <ON>
NOTE: Move strobe light in a ``W'' pattern while

2
to find reflective blade tracking targets.
(6). Fly aircraft at 80 KIAS and record

vertical position of each rotor blade
3
tracking tip. WITNESS
HOLES
4
(7). Fly aircraft at 120 KIAS and record
vertical position of each rotor blade 1
tracking tip.
(8). Do the Main Rotor Balance (In Flight)

procedure. 3 LENGTHEN
E. Pitch Change Link Adjustment 2
(Ref. Figure 202)
(Ref. CSPSPM)
Item Nomenclature
9G18-004
C702 Lockwire 1. PITCH CHANGE LINK
2. ROD END
3. NUTS
4. BARREL
(1). Remove and discard lockwire from nuts
(3). Loosen nuts. Figure 202. Pitch Change Link Adjustment
Page 203
F. Main Rotor Blade Tab Adjustment (2). Install trim tab gauge (2) on main rotor
blade (3) at trim tab.
(Ref. Figure 203)
(3). Install tab bending tool (4) on trim tab.
Special Tools NOTE: Trim tab is very sensitive. Only small
(Ref. CSPSPM) amounts of force are necessary to bend tab.
Item Nomenclature One mil is equal to 0.001 inch.
T902 Main Rotor Blade Tab Bending Tool (4). Bend tab up or down as necessary. Do
not bend tab more than 0.085 in.
(0.215 mm) from ``0.
(1). Install calibration plate (1) in trim tab
gauge (2). Adjust dial indicator (T902)to (5). Remove tab bending tool (T902) and
read ``0. trim tab gauge. Record changes.
2
3
4
9G18-006
1. CALIBRATION PLATE 3. MAIN ROTOR BLADE
2. TRIM TAB GAUGE 4. ROTOR BLADE TRIM TAB BENDING TOOL
Figure 203. Main Rotor Blade Tab Adjustment
G. Main Rotor Balance (On Ground) (3). Do the ground balance part of Balance
Display Measurement Menu procedure
Rotor Vibrations (Ref. CSP-900RMM-3, Section
WARNING 95-30-00). Record results.
(4). Do the Main Rotor Solutions Options
(1). Start aircraft, refer to current Rotor Menu procedure (Ref. CSP-900RMM-3,
craft Flight Manual (Ref. Section Section 95-30-00) to find necessary
01-00-00, Table 201). adjustments to get correct balance.
(5). Make balance adjustments.
(2). Do the Collect M/R Data Run XX Menu
procedure (Ref. CSP-900RMM-3, (6). Repeat steps (1). through (4). until
Section 95-30-00). balance is 0.3 IPS or less.
Page 204
H. Main Rotor Balance (In Flight) Blade number one is located above nose of
helicopter when swashplate interrupter is
Rotor Vibrations above azimuth sensor. Blades number 2,
WARNING 3, 4, and 5 are numbered in sequence op
posite the direction the rotor turns.
(1). Start aircraft, refer to current Rotor
craft Flight Manual (Ref. Section (1). Find main rotor blade indicated by
01-00-00, Table 201). Main Rotor Solutions Options Menu
procedure (Ref. CSP-900RMM-3,
(2). Do the Collect M/R Data Run XX Menu Section 95-30-00)
procedure (Ref. CSP-900RMM-3, NOTE: Balance weights are approximately
Section 95-30-00). 13.6 grams each. No more than 13 balance
weights (approximately 177 grams) can be
(3). Do the complete Balance Display
installed on each pitch case.
Measurement Menu procedure (Ref.
CSP-900RMM-3, Section 95-30-00). (2). Find the correct quantity of weight to
Record results. add or remove.
(4). Do the Main Rotor Solutions Options (3). Remove sealant from bolts (6), washers
Menu procedure (Ref. CSP-900RMM-3, (7), and bonding jumpers (8).
Section 95-30-00) to find necessary (4). Remove bolts (6), washers (7), bonding
adjustments to get correct balance. jumpers (8), and weights (3) (if instaled).
(5). Make balance adjustments. (5). Prepare surface for electrical bond (Ref.
CSP-SPM).
(6). Repeat steps (1). through (4). until
NOTE:
balance is 0.2 IPS or less.
Change bolt length as necessary when
I. Pitch Case Weight Adjustment you add or remove weights.
(Recommended Location) If weights were not installed before, you
must use a different part number bolt
(Ref. Figure 204) when you install weights (Ref.
CSP-900IPL-4).
Consumable Materials (6). Install balance weights, bonding
(Ref. CSPSPM) jumpers, washers, and bolts. Torque
Item Nomenclature bolts 20-25 in-lb (2.26-2.82 Nwm) and
C229 Sealant, Conductive safety with lockwire (C702).
C702 Lockwire (7). Test bolts for class S electrical bond
(Ref. CSP-SPM.
NOTE: Sealant, Conductive (C229)
Pitch case weight location is the recom
mended location for main rotor balance
adjustments.
Hub weight location is an alternative (8). Environmentally seal bolts, washers,
location and can be used along with the and bonding jumpers, use sealant
pitch case location. (C229) (Ref CSP-SPM).
Page 205
J. Hub Weight Adjustment (Alternative (2). Find the correct quantity of weight to
Location) add or remove.
(Ref. Figure 204) (3). Remove nuts (5),washers (2), balance
weights (3) (if installed), screws (1), and
NOTE:
washers (2).
Pitch case weight location is the recom
mended location for main rotor balance NOTE:
adjustments.
No more than 8 each 900R2101024-101
Hub weight location is an alternative or 16 each 900R2101024-103 balance
location and can be used along with the weights (approximately 218 grams) can
pitch case location. be installed at each hub weight location.
Blade number one is located above nose of Install the same quantity of balance
helicopter when swashplate interrupter is weights on top and bottom of hub plate.
above azimuth sensor. Blades number 2,
3, 4, and 5 are numbered in sequence op Change screw length as necessary when
posite the direction the rotor turns. you add or remove weights.
(1). Find main rotor blade indicated by (4). Install balance weights, screws,
Main Rotor Solutions Options Menu washers, and nuts. Torque nuts 20-25
procedure (Ref. CSP-900RMM-3, in-lb (2.26-2.82 Nwm) and safety
Section 95-30-00) screws with lockwire (C702).
6 6
7
7
8
8
1
3 1
2
3
5 2
4
2
4
9G18-007A
1. SCREW 5. HUB PLATE
2. WASHER 6. BOLT
3. BALANCE WEIGHT 7. WASHER
4. NUT 8. BONDING JUMPER
Figure 204. Main Rotor Balance Adjustment
Page 206
2. AntiTorque Fan Assembly Balance (3). Do the NOTAR Balance Collect Data
Menu procedure (Ref. CSP-900RMM-3,
A. AntiTorque Fan Balance Using Balance Section 95-30-00)
Monitoring System (BMS) in IIDS
Rotor Vibrations (4). Do the Display NOTAR Measure
WARNING ments Menu procedure (Ref.
(1). Start one engine, refer to current
Rotorcraft Flight Manual (Ref. Section NOTE: No more than 0.15 IPS fan balance is
01-00-00, Table 201). permitted.
(2). Set main rotor RPM to 100% for two
minutes. (5). Do the NOTAR Balance Solutions
Menu procedure (Ref. CSP-900RMM-3,
NOTE: Section 95-30-00). If necessary, record
Make sure directional control pedals are recommended balance adjustment.
set to approximately one inch forward
right pedal to get minimum fan pitch be NOTE: Try to balance the fan to (0.05 IPS).
fore you do this procedure.
You can also look at the torque indication (6). If necessary, change anti-torque fan
on the IIDS and move directional control balance weight.
pedals to get the lowest torque indication.
This will give you an accurate indication (7). If necessary, do steps (1). thru (6).
the fan is at minimum pitch. again.
Page 207
B. AntiTorque Fan Balance Weight Change NOTE:

(Ref. Figure 205) One gram of balance weight change gives
(1). Remove baggage compartment closeout approximately 0.18 IPS of balance
panels and soft insulation panels (Ref change.
Section 25-50-00). If more than three weights are added at
(2). Remove anti-torque fan diffuser lower one time, weigh the total number of
half (Ref. Section 53-00-00). weights with a scale.
(3). Number balance weight studs (1) on (a). Remove nut (3).
anti-torque fan (2) (Ref. Figure 205).
Use a permanent marker. (b). Remove or install balance weights
(4).
NOTE: Thickness of weights on balance stud
can be no more than 0.20 in. (5.08 mm). Do not tighten nut on balance
CAUTION weight stud too much. If you
(4). Add or remove balance weights re
corded from Balance Solutions Menu tighten nut too much, balance stud collar
procedure (Ref. Table 201). can loosen next time nut is removed.
Table 201. AntiTorque Fan Recommended (c). Install nut. Torque nut.
Balance Weights (5). Install lower diffuser and duct (Ref.
Thick I.D. O.D. Weight Section 53-00-00).
Part Number (in.) (in.) (in.) (Grams)
(6). Install baggage compartment closeout
AN960KD416L 0.016 0.265 0.500 0.103 panels and soft insulation panels (Ref
Section 25-50-00).
AN960416L 0.032 0.265 0.500 0.572
AN960KD416 0.063 0.265 0.500 0.407
AN960C416 0.063 0.265 0.500 1.144
HS306325L 0.016 0.263 0.528 0.121
HS306225L 0.016 0.263 0.528 0.339
HS306325 0.032 0.263 0.528 0.241
HS306225 0.032 0.263 0.528 0.667
HS306325H 0.063 0.263 0.528 0.482
HS306225H 0.063 0.263 0.528 1.355
HS306326L 0.016 0.263 0.619 0.181
HS306226L 0.016 0.263 0.619 0.507
HS306326 0.032 0.263 0.619 0.361
HS306226 0.032 0.263 0.619 1.015
HS306326H 0.063 0.263 0.619 0.723
HS306226H 0.063 0.263 0.619 2.029
HS306327L 0.016 0.263 0.800 0.329
HS306227L 0.016 0.263 0.800 0.922
HS306327 0.032 0.263 0.800 0.657
HS306227 0.032 0.263 0.800 1.844
HS306327H 0.063 0.263 0.800 1.314
HS306227H 0.063 0.263 0.800 3.689
Page 208
12 13
2
11 1
3
10 2
9 3
1
8 4
7 5
6
BALANCE STUD ASSEMBLY

9G18-005B
1. BALANCE STUD 4. BALANCE WEIGHTS
2. ANTITORQUE FAN 5. AZIMUTH SENSOR INTERRUPTER RIVET
3. NUT
Figure 205. AntiTorque Fan Balance Weight Adjustment
Page 209
3. Main Rotor Autorotation RPM (3). Record main rotor RPM and density
altitude.
A. Autorotation RPM Adjustment
(4). Refer to autorotation RPM chart in
(Ref. Figure 206) Figure 206 for correct rotor RPM.
NOTE:
Rotor Vibrations
WARNING To increase autorotation RPM, lengthen
pitch change links (decrease blade pitch).
(1). Operate aircraft at an altitude suffi To decrease autorotation RPM, shorten
cient for doing an autorotation, refer to pitch change links (increase blade pitch).
current applicable Rotorcraft Flight
Manual (Ref. Section 01-00-00, If you turn pitch link barrel one flat, you
Table 201). will change rotor RPM by approximately
0.6%.
(2). Do the autorotation at a stabilized (5). If autorotation RPM is not within
airspeed of 70 KIAS with collective range, adjust all pitch change links
stick full down. equally as shown on autorotation RPM
chart.
NOTE: If aircraft is at or near gross weight lim
it and there is high density altitude, it is (6). When autorotation RPM is correct, do
possible the procedure can not be done with the hover and forward flight balance
collective stick full down. Refer to note on procedures to make sure rotor vibration
Sheet 2 of Figure 206 for alternative collec levels are 0.2 IPS or less (Ref. Main
tive position at higher gross weights. Rotor Balance (In Flight)).
Page 210
MD900 AUTOROTATION RPM CHART

COLLECTIVE SET TO 0%
EXAMPLE ROTORCRAFT
GROSS WEIGHT - LBS WEIGHT: 4920 LBS
3600 4000 4400 4800 5200 5600 6000
20000
18000
EXAMPLE:
ROTORCRAFT WEIGHT: 4920 LBS.
DENSITY ALTITUDE: 500 FT.
16000 *MAIN ROTOR RPM FOR THIS WEIGHT AND DENSITY
ALTITUDE SHOULD BE SET BETWEEN 101% AND 102% NR
WITH COLLECTIVE CONTROL LEVER FULL DOWN.
14000
12000
DENSITY ALTITUDE - FT
10000
8000
6000
4000
EXAMPLE DENSITY
ALTITUDE: 2000
500 FEET
-2000
88 90 92 94 96 98 100 102 104 106 108
89 91 93 95 97 99 101 103 105 107
*
Figure 206. Autorotation RPM Chart (Sheet 1 of 2)
Page 211
MD900 AUTOROTATION RPM CHART EXAMPLE ROTORCRAFT

WEIGHT: 5860 LBS
COLLECTIVE SET TO 10%
3600 3800 4000 4200 4400 4600 4800 5000 5200 5400 5600 5800 6000 6200 6400
20000
18000
EXAMPLE:
ROTORCRAFT WEIGHT: 5860 LBS.
DENSITY ALTITUDE: 500 FT.
*MAIN ROTOR RPM FOR THIS WEIGHT AND DENSITY

16000 ALTITUDE SHOULD BE SET BETWEEN 102% AND 103% NR
WITH COLLECTIVE CONTROL LEVER SHOWN AT 10% CLP
ON THE IIDS ALPHA NUMERIC DISPLAY.
14000
DENSITY ALTITUDE - FT
12000
10000
8000
6000
4000
EXAMPLE DENSITY
ALTITUDE:
500 FEET 2000
108
107
0
106
105
-2000
88 90 92 94 96 98 100 102 104
89 91 93 95 97 99 101 103
PERCENT NR *
9G18-002-2A
Figure 206 Autorotation RPM Chart (Sheet 2 of 2)
Page 212
Chapter
ENVIRONMENTAL
CONTROL SYSTEM
TABLE OF CONTENTS
21-20-00 Vent System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A

1. Vent System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Vent System Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
A. Inlet Duct . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
B. Water Separator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
C. Vent Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
D. Air Supply Plenum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
E. Air Ducts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
F. Crew Station Gasper Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
G. Passenger Gasper Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Figure 1.Vent System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Fault Isolation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
1. Vent System Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Table 101.Vent System Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Figure 101.Vent System Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
1. Vent System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
A. Vent System Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
Figure 201.Vent System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
2. Water Separator Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
A. Water Separator Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
B. Water Separator Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
Figure 202.Water Separator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
3. Vent System Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
A. Vent System Fan Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
B. Vent System Fan Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
Figure 203.Recirculating Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
Figure 204.Vent Air Supply Plenum Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
4. Vent Air Supply Plenum Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
A. Vent Air Supply Plenum Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
B. Vent Air Supply Plenum Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
Figure 205.Gasper Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
5. Gasper Assembly Crew Station . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
A. Gasper Assembly (Crew Station) Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
B. Gasper Assembly (Crew Station) Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
6. Gasper Assembly, Crew Station Overhead . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208
Page i

A. Gasper Assembly, Crew Station (Overhead) Removal . . . . . . . . . . . . . . . . . . . . . . . 208
B. Gasper Assembly, Crew Station (Overhead) Installation . . . . . . . . . . . . . . . . . . . . 208
7. Gasper Assembly, Passenger Compartment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208
A. Gasper Assembly (Passenger Compartment) Removal . . . . . . . . . . . . . . . . . . . . . . 208
B. Gasper Assembly (Passenger Compartment) Installation . . . . . . . . . . . . . . . . . . . . 208
21-40-00 Heat / Defog System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A
1. Heat / Defog System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
A. Engine Bleed Air Check Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
B. Flow Control Shutoff Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
C. Heat Flow Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
D. Heater Control Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
E. Aft Cabin Heat Ejector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
F. Heat / Defog Bleed Air Tubes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
G. Heat / Defog Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
H. Heat / Defog Control Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
I. Heat / Defog Ejector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
J. Plenum Heat / Defog Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
K. Defog Manifolds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
L. Foot Heater Control Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
M. Foot Heater Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Figure 1.Heat / Defog System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Figure 2.Heat / Defog System Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Fault Isolation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
1. Heat / Defog System Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Table 101.Heat / Defog System Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Figure 101.Heat / Defog System Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . 103
Figure 102.Utility Control Panel (Heat / Defog) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
1. Heat/Defog Ejector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
A. Heat/Defog Ejector Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
B. Heat/Defog Ejector Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
2. Heat/Defog Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 402
A. Heat/Defog Valve Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 402
B. Heat/Defog Valve Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 402
3. Heat/Defog Control Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 403
A. Heat/Defog Control Cable Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 403
Page ii

B. Heat/Defog Control Cable Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 403
Figure 401.Heat/Defog Valve, Ejector, and Control Cable . . . . . . . . . . . . . . . . . . . 404
4. Defog Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 405
A. Defog Manifold Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 405
B. Defog Manifold Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 405
5. Foot Heater Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 405
A. Foot Heater Valve Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 405
B. Foot Heater Valve Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 405
6. Foot Heater Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 406
Figure 402.Defog Manifold, Foot Heater Valve, Control Cable . . . . . . . . . . . . . . . 406
A. Foot Heater Cable Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 406
B. Foot Heater Cable Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 406
7. Aft Cabin Heat Ejector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 407
A. Aft Cabin Heat Ejector Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 407
B. Aft Cabin Heat Ejector Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 407
8. Heating System Flow Control Valve Single Ball . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 408
A. Heating System Flow Control Valve Single Ball Removal . . . . . . . . . . . . . . . . . . . 408
B. Heating System Flow Control Valve Single Ball Installation . . . . . . . . . . . . . . . . . 408
9. Flexible - Heater Control Cable Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 408
A. Flexible - Heater Control Cable Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . 408
B. Flexible - Heater Control Cable Assembly Installation . . . . . . . . . . . . . . . . . . . . . . 409
Figure 403.Cabin Heat Ejector, Single Ball Flow Control Valve,
Flexible - Heater Control Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 410
10. Engine Bleed Air Check Valve (900 CONFIG) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 411
A. Engine Bleed Air Check Valve Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 411
B. Engine Bleed Air Check Valve Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 411
11. Flow Control Shutoff Valve Assembly (900 CONFIG) . . . . . . . . . . . . . . . . . . . . . . . . . 412
A. Flow Control Shutoff Valve Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 412
B. Flow Control Shutoff Valve Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 412
12. Valve To Deck Tube Assembly (900 CONFIG) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 413
A. Valve to Deck Tube Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 413
B. Valve to Deck Tube Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 413
Figure 404.Engine Bleed Air Check Valve/Flow Control Shutoff Valve
(900 CONFIG) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 414
13. Engine Bleed Air Check Valve (902 CONFIG) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 415
A. Engine Bleed Air Check Valve Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 415
B. Engine Bleed Air Check Valve Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 415
14. Flow Control Shutoff Valve Assembly (902 CONFIG) . . . . . . . . . . . . . . . . . . . . . . . . . 415
Page iii

A. Flow Control Shutoff Valve Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 415
B. Flow Control Shutoff Valve Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 415
15. Valve To Deck Tube Assembly (902 CONFIG) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 416
A. Valve to Deck Tube Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 416
B. Valve to Deck Tube Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 416
Figure 405.Engine Bleed Air Check Valve / Flow Control Shutoff Valve
(902 CONFIG) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 417
16. Threadless Flexible Coupling Seal Assembly (900 CONFIG) . . . . . . . . . . . . . . . . . . . 419
A. Threadless Flexible Coupling Seal Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 419
Figure 406.Threadless Flexible Coupling Seal Replacement (900 CONFIG) . . 419
17. Heat/Defog Tube Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 420
A. Heat/Defog Tube Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 420
B. Heat/Defog Tube Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 420
Figure 407.Heat/Defog Tube Assembly Replacement (Sheet 1 of 2) . . . . . . . . . . 421
Inspection/Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601
1. Heat/Defog System Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601
A. Heat/Defog System Bleed Air Engine/Firewall Inspection (Area 5) . . . . . . . . . . . 601
B. Heat/Defog Tube Assemblies Inspection (Area 6) . . . . . . . . . . . . . . . . . . . . . . . . . . . 601
C. Under Floor Tube Assemblies Inspection (Area 1 and 2) . . . . . . . . . . . . . . . . . . . . . 601
D. Control Cables Inspection (Area 1 and 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601
E. Aft Cabin Heat Ejector Inspection (Area 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 602
F. Flow Control Single Ball Valve Inspection (Area 2) . . . . . . . . . . . . . . . . . . . . . . . . . 602
G. Heat/Defog Ejector Inspection (Area 1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 602
H. Heat/Defog Valve Inspection (Area 1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 602
I. Rubber Ducts and Hoses Inspection (Area 1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 602
J. Defog Manifold Inspection (Area 1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 602
K. Foot Heater Valves Inspection (Area 1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 602
Figure 601.Heat/Defog System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 603
Figure 602.Engine Bleed Air Check Valve / Flow Control Shutoff Valve . . . . . . 604
2. Heat/Defog System Leak Check Functional Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 606
Figure 603.Heat/Defog Leak Check Functional Test . . . . . . . . . . . . . . . . . . . . . . . . 608
21-50-00 Air Conditioning System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A
1. Air Conditioning System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
A. Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
B. Compressor Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
C. Lines and Tubing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
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D. Condenser Fans (EARLY CONFIG) - . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
E. Cooling Blowers (CURRENT CONFIG)- . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
F. Condenser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
G. Receiver Dehydrator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
H. Sight Glass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
I. High Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
J. Low Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
K. Thermostatic Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
L. Thermostatic Expansion Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
M. Evaporator Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
N. Evaporator Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
O. Three-Way Valve Duct Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
P. Three Way Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Q. Three-Way Valve Control Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Figure 1.Air Conditioning System - EARLY CONFIG . . . . . . . . . . . . . . . . . . . . . . 4
Figure 2.Air Conditioning System - CURRENT CONFIG . . . . . . . . . . . . . . . . . . . 5
Figure 3.Air Conditioning System Diagram (EARLY CONFIG) . . . . . . . . . . . . . . 6
Figure 4.Air Conditioning System Diagram (CURRENT CONFIG) . . . . . . . . . . 7
Fault Isolation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
1. Air-Conditioning System Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Table 101.Air-Conditioning System Troubleshooting . . . . . . . . . . . . . . . . . . . . . . 101
Figure 101.Air-Conditioning System (Vapor Cycle Cooling System) -
EARLY CONFIG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
Figure 102.Air-Conditioning System (Vapor Cycle Cooling System) -
CURRENT CONFIG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
Figure 103.Air-Conditioning System Wiring Diagram (Sheet 1 of 2) . . . . . . . . . 105
Figure 104.Utility Control Panel (Air-Conditioning System) . . . . . . . . . . . . . . . . 107
Removal / Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
1. Compressor Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
A. Compressor Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
B. Operation Without the Compressor Assembly Installed . . . . . . . . . . . . . . . . . . . . . 401
C. Compress Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
Figure 401.Removal and Installation of the Compressor (Right Engine) . . . . . . 402
Figure 402.Removal and Installation of Three-Way Valve Cable and Duct . . . 404
2. Three-Way Valve Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 405
A. Three-Way Valve Cable Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 405
B. Three-Way Valve Cable Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 405
3. Three-Way Valve Duct Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 405
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A. Three-Way Valve Duct Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 405
B. Three-Way Valve Duct Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 405
Figure 403.Removal and Installation of the Evaporator Fan . . . . . . . . . . . . . . . . 406
4. Evaporator Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 407
A. Evaporator Fan Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 407
B. Evaporator Fan Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 407
Figure 404.Removal and Installation of the Evaporator (EARLY CONFIG) . . . 408
5. Evaporator Outlet Shroud (EARLY CONFIG) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 409
A. Outlet Shroud Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 409
B. Outlet Shroud Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 409
6. Evaporator Assembly (EARLY CONFIG) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 409
A. Evaporator Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 409
B. Evaporator Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 410
7. Expansion Valve (EARLY CONFIG) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 410
A. Expansion Valve Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 410
B. Expansion Valve Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 410
8. Expansion Valve Strainer (EARLY CONFIG) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 411
A. Strainer Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 411
B. Strainer Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 411
9. Evaporator Inlet Shroud (EARLY CONFIG) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 411
A. Inlet Shroud Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 411
B. Inlet Shroud Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 411
10. Thermostatic Switch (EARLY CONFIG.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 411
A. Thermostatic Switch Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 411
B. Thermostatic Switch Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 411
11. Evaporator Aft Mounting Bracket (EARLY CONFIG) . . . . . . . . . . . . . . . . . . . . . . . . . 411
A. Bracket Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 411
B. Bracket Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 412
Figure 405.Removal and Installation of the Evaporator (CURRENT CONFIG.) 413
12. Evaporator Inlet Shroud (CURRENT CONFIG) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 414
A. Inlet Shroud Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 414
B. Inlet Shroud Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 414
13. Evaporator Assembly (CURRENT CONFIG) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 414
A. Evaporator Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 414
B. Evaporator Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 415
14. Evaporator Outlet Shroud (CURRENT CONFIG) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 415
A. Outlet Shroud Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 415
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B. Outlet Shroud Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 415
15. Thermostatic Switch (CURRENT CONFIG) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 416
A. Thermostatic Switch Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 416
B. Thermostatic Switch Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 416
Figure 406.Removal and Installation of the Condenser (EARLY CONFIG) . . . 418
16. Condenser Fan (EARLY CONFIG) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 419
A. Condenser Fan Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 419
B. Condenser Fan Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 419
17. Condenser Transition Duct (EARLY CONFIG) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 419
A. Condenser Transition Duct Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 419
B. Condenser Transition Duct Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 419
18. Condenser (EARLY CONFIG) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 419
A. Condenser Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 419
B. Condenser Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 419
19. Condenser Inlet Screen (EARLY CONFIG) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 420
A. Inlet Screen Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 420
B. Inlet Screen Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 420
20. Condenser Exit Screen (EARLY CONFIG) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 420
A. Exit Screen Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 420
B. Exit Screen Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 420
Figure 407.Removal and Installation of the Condenser (CURRENT CONFIG) 422
21. Condenser (CURRENT CONFIG) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 423
A. Condenser Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 423
B. Condenser Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 423
Figure 408.Removal and Installation of the Receiver Dehydrator . . . . . . . . . . . . 426
22. Receiver Dehydrator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 427
A. Receiver Dehydrator Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 427
B. Receiver Dehydrator Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 427
23. Receiver Dehydrator Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 427
A. Bracket Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 427
B. Bracket Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 428
Figure 409.AC System Installation (Sheet 1 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . 429
24. Low-Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 431
A. Low-Pressure Switch Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 431
B. Low-Pressure Switch Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 431
25. High-Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 432
A. High-Pressure Switch Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 432
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B. High-Pressure Switch Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 432
26. Compressor Inlet Hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 432
A. Inlet Hose Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 432
B. Inlet Hose Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 432
27. Compressor Outlet Hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 432
A. Outlet Hose Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 432
B. Outlet Hose Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 432
28. High-Pressure Tubes (EARLY CONFIG) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 433
A. Mid-Section to Evaporator Tube Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 433
B. Mid-Section to Evaporator Tube Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 433
C. High-Pressure Switch to Mid-Section Tube Removal . . . . . . . . . . . . . . . . . . . . . . . 433
D. High-Pressure Switch to Mid-Section Tube Installation . . . . . . . . . . . . . . . . . . . . 433
E. Receiver Dehydrator to High-Pressure Switch Tube Removal . . . . . . . . . . . . . . . 433
F. Receiver Dehydrator to High-Pressure Switch Tube Installation . . . . . . . . . . . . . 434
G. Receiver Dehydrator to Deck Hose Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 434
H. Receiver Dehydrator to Deck Hose Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 434
I. Baggage Closet to Deck Tube Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 434
J. Baggage Closet to Deck Tube Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 434
K. Deck to Baggage Closet Tube Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 435
L. Deck to Baggage Closet Tube Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 435
M. Upper Deck Elbow Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 435
N. Upper Deck Elbow Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 435
O. Baggage Closet Tube Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 435
P. Baggage Closet Tube Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 436
Q. Keel Beam to Floor Tube Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 436
R. Keel Beam to Floor Tube Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 436
S. Floor to Keel Beam Tube Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 436
T. Floor to Keel Beam Tube Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 436
U. Condenser to Keel Beam Tube Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 436
V. Condenser to Keel Beam Tube Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 437
W. Keel Beam to Condenser Tube Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 437
X. Keel Beam to Condenser Tube Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 437
29. High-Pressure Tubes (CURRENT CONFIG) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 437
A. Evaporator to Sight Glass Tube Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 437
B. Evaporator to Sight Glass Tube Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 437
C. Sight Glass Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 437
D. Sight Glass Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 438
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E. Sight Glass to Mid-Section Tube Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 438
F. Sight Glass to Mid-Section Tube Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 438
G. Mid-Section to Receiver Dehydrator Tube Removal . . . . . . . . . . . . . . . . . . . . . . . . . 438
H. Mid-Section to Receiver Dehydrator Tube Installation . . . . . . . . . . . . . . . . . . . . . . 438
I. Receiver Dehydrator to Tee Tube Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 438
J. Receiver Dehydrator to Tee Tube Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 439
K. Left Condenser to Tee Tube Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 439
L. Left Condenser to Tee Tube Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 439
M. Right Condenser to Tee Tube Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 439
N. Right Condenser to Tee Tube Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 439
O. Left Condenser to High-Pressure Switch Tube Removal . . . . . . . . . . . . . . . . . . . . 439
P. Left Condenser to High-Pressure Switch Tube Installation . . . . . . . . . . . . . . . . . . 440
Q. High-Pressure Switch to Tee Tube Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 440
R. High-Pressure Switch to Tee Tube Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 440
S. Tee to Right Condenser Tube Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 440
T. Tee to Right Condenser Tube Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 440
Figure 410.Removal and Installation of Low-Pressure Lines
(EARLY CONFIG) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 442
30. Low-Pressure Lines (EARLY CONFIG) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 443
A. ECS Mid-Section to Low-Pressure Switch Tube Removal . . . . . . . . . . . . . . . . . . . 443
B. ECS Mid-Section to Low-Pressure Switch Tube Installation . . . . . . . . . . . . . . . . 443
C. ECS Evaporator to Mid-Section Tube Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 443
D. ECS Evaporator to Mid-Section Tube Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 444
Figure 411.Removal and Installation of Low-Pressure Lines
(CURRENT CONFIG) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 446
31. Low-Pressure Lines (CURRENT CONFIG) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 447
A. ECS Mid-Section to Low-Pressure Switch Tube Removal . . . . . . . . . . . . . . . . . . . 447
B. ECS Mid-Section to Low-Pressure Switch Tube Installation . . . . . . . . . . . . . . . . 447
C. ECS Evaporator to Mid-Section Tube Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 447
D. ECS Evaporator to Mid-Section Tube Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 448
Inspection/Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601
1. Air Conditioning System Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601
A. Freon Compressor Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601
B. Receiver Dehydrator Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601
C. Evaporator Assembly Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601
D. High Pressure Switch Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601
E. Low Pressure Switch Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601
Page ix

F. Evaporator Fan Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601
G. Three Way Valve Duct Assembly Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601
H. Three Way Valve Control Cable Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601
I. Line and Tube Assemblies Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 602
J. Condenser Assembly Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 602
K. Condenser Fan Inspection (EARLY CONFIG) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 602
L. Condenser Scoop (EARLY CONFIG) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 602
Page x
Section
212000
Vent System
VENT SYSTEM
1. Vent System switch controls the vent fan and air condition
ing. VENT LOW provides vent air at a low
The vent system introduces outside air into setting. VENT HIGH provides air at a high
the cabin and crew compartment. Air enters setting, selected from the center console utility
through an air inlet duct above the transmis panel assembly.
sion deck. Air is routed into a water separator
to remove moisture (rain), while maintaining a D. Air Supply Plenum
constant air flow. A two speed vent fan, located
on the transmission deck is used to induce The air supply plenum distributes the air flow
airflow. Air enters the cockpit and cabin area from the inlet duct and vent fan to the air
through a plenum, air ducts and gasper ducts. The air supply plenum is constructed of
assemblies. composite fiberglass.
E. Air Ducts
2. Vent System Components
Air ducts route air directly to the gasper
A. Inlet Duct assemblies from the air supply plenum. The
air ducts are constructed of silicon rubber
An inlet duct is attached to the right side of coated woven fiberglass, with a nylon heli-coil
the forward swashplate fairing assembly. An reinforcement.
inlet hole measuring five inches in diameter is
covered with an air scoop and screen to allow F. Crew Station Gasper Assemblies
outside air in for the air vent system.
Four crew station gasper assemblies allow air
B. Water Separator to be directed into the cockpit. The gasper
assemblies are constructed of aluminum and
The water separator is located immediately are capable of delivering a flow volume of 20
downstream from the inlet duct. Outside air cubic feet per minute. The gasper assemblies
enters the water separator. Moisture (rain) utilize an inner cylindrical disc that allows air
entering the water separator with fresh air is to discharge at adjustable volume rates. A
centrifugally extracted to the bottom of the finger rotation of the assembly will alternate
water separator when the air makes a 180 the gasper assembly's cylindrical disc to
degree turn and flows into a vent fan. Water is change air flow discharge volume.
drained from the separator when a rubber
check valve opens into on the transmission G. Passenger Gasper Assemblies
deck.
Passenger gasper assemblies are located at six
C. Vent Fan various locations in the passenger compart
ment ceiling. Gasper assemblies are
The vent fan is used to initiate and sustain air constructed of aluminum and are capable of
flow at 180 cubic feet per minute. The fan is a delivering air at a flow volume of 20 cubic feet
two speed vane axial type with an aluminum per minute. Gasper assemblies utilize an inner
impeller. The fan is powered by a 28 vdc cylindrical disc to discharge air at adjustable
brushless motor. The vent fan is mounted at volume rates. A finger rotation of the assembly
fuselage station 185.5 on the right side of the will alternate the gasper assembly's cylindrical
transmission deck. A five position AC/VENT disc to change the air flow discharge volume.
Page 1
21-20-00 Original
CABLE HANDLE AIR DUCTING

BRACKET ASSEMBLY
AIR DUCTING
GASPER ASSY
COCKPIT BULKHEAD
PLENUM ASSY
FRESH AIR INLET
AIR DUCTING
GASPER ASSY
OVERHEAD WATER SEPARATOR
CREW STATION GASPER ASSY
COCKPIT
FLEXIBLE GASPER ASSY
SERIAL NUMBERS 0039-SUBSEQUENT PASSENGER
AIR DUCTING
COMPARTMENT
VENT FAN
FLEXIBLE
AIR DUCTING AIR DUCTING
DOOR PILLAR PLENUM
AIR DUCTING
DUCT ASSY
ROOF DECK FLEXIBLE
AIR DUCTING AIR DUCTING
VENT AIR SUPPLY GASPER ASSY
GASPER ASSY
GASPER ASSY OVERHEAD PLENUM PASSENGER
CREW STATION
CREW STATION COMPARTMENT
GASPER ASSY PASSENGER
COMPARTMENT
AIR DUCTING
DOOR PILLAR PLENUM
GASPER ASSY
CREW STATION
9G21012B
Figure 1. Vent System
Page 2
Original 21-20-00
VENT SYSTEM
FAULT ISOLATION
1. Vent System Troubleshooting Troubleshooting tables should be used with
serviceability checks and other detailed
(Ref. Figure 101) procedures in this and other chapters of the
manual.
The following troubleshooting procedures are a Comprehensive wiring diagrams are available
brief summary of vent system faults which in the Rotorcraft Maintenance Manual
may be encountered (Ref. Table 101). CSP-900RMM-3 (Ref. Section 98-40-00).
Table 101. Vent System Troubleshooting
Vent fan inoperative. Circuit Breaker VENT EVAP Replace or reset VENT EVAP 206000
(CB18) Open. circuit breaker (CB18) as
required.
Faulty AC/VENT switch. Remove and replace vent 960000
switch.
Open ground wire from Test and repair wiring. 206000

AC/Vent Fan switch to
GS 104D ground stud.
Faulty K100 power relay. Remove and replace K100 960000
power relay.
Faulty vent fan motor. Replace vent fan motor. 212000

Faulty wiring. Test and repair wiring. 206000
Page 101
K100
A620 POWER RELAY
ELECTRICAL LOAD CENTER A413
B2 B1
RECIRCULATING FAN
W123 W306
A606 CB18
UTILITY CONTROL PANEL VENT/EVAP J8 P381 P513 J1
A2 A1
28VDC C A 28VDC
S3 W124
AC/VENT SWITCH
J1 P117 P374 J2 X1 D SPEED CONTROL
COOL HI
1 X2
2 A 22 B PWR GND
COOL LO J3 P377 J155 P155
CA1 3 OFF E PWR GND
4 VENT LO 21 20 F
E
5 VENT HI GS400
1 COOL HI A612
2 COOL LO FWD INTERCONNECT
CA2 3 OFF PANEL
4 VENT LO
W123
5 P172 J1 J1 P171
VENT HI
C 43 10
COOL HI D
1
2 COOL LO
CA3
3 OFF
4 VENT LO
5
VENT HI
E E GS104-D
E H E GS106-J
9G21025A
Figure 101. Vent System Wiring Diagram
Page 102
Original 21-20-00
VENT SYSTEM
1. Vent System (10). Inspect electrical connector for corro
sion. Verify fan for two-speed opera
(Ref. Figure 201) tion.
A. Vent System Inspection (11). Inspect air plenum duct assemblies for
(1). Open right forward access door assem cracks, tears, deterioration, deforma
bly R155 and transmission access door tion and security. Repair or replace as
assembly R210 (Ref. Section 06-00-00). required.
(2). Remove cabin compartment interior (12). Inspect distribution flexible ducts for
roof panels (Ref. Section 25-20-00). cuts, deterioration and collapsed nylon
coiled supports. Repair or replace as
(3). Inspect air scoop for cracks. Repair or required.
replace as required.
(13). Inspect door pillar plenum duct for
(4). Inspect inlet air screen for cracked and cracks. Repair or replace as required.
broken wire mesh. Inspect for obstruc
tion, corrosion and security. Repair or (14). Inspect crew compartment gasper
replace as required. assemblies for cracks, cylindrical disc,
cap and ball socket for freedom of
(5). Inspect inlet duct for cracks, deforma operation. Repair or replace as re
tion, and security. Repair or replace as quired.
required.
(15). Inspect cabin compartment gasper
(6). Inspect water separator for cleanness,
assemblies for cracks, cylindrical disc,
cracks, corrosion and security. Inspect
cap and ball socket for freedom of
welds at mounting brackets for cracks.
operation. Repair or replace as re
Repair or replace as required.
quired.
(7). Inspect water separator rubber drain
check valve for deterioration. Repair or (16). Install cabin compartment interior roof
replace as required. panels (Ref. Section 25-20-00).
(8). Inspect fan assembly for cleanness. (17). Close right-hand forward access door
assembly R155 and transmission access
(9). Inspect fan mounting brackets for door assembly R210 (Ref. Section
cracks. Repair or replace as required. 06-00-00).
Page 201
21-20-00 Original
9
13
9
9
14 2
9 15
5
4 6
10 14 3
SERIAL NUMBERS 0039-SUBSEQUENT 1

5
9
11 9
9 5
7 6
10
6
12
11
12
SERIAL NUMBERS 0008-0038
9G21028B
1. RECIRCULATING FAN 9. AIR DUCTING CREW COMPARTMENT

2. VENT AIR SCOOP 10. OVERHEAD GASPER CREW COMPARTMENT
3. FRESH AIR INLET 11. AIR DUCTING DOOR FRAME
4. WATER SEPARATOR 12. GASPER ASSEMBLY CREW STATION
5. CABIN AIR DUCTING 13. CABLE HANDLE BRACKET ASSEMBLY
6. GASPER ASSEMBLY (PASSENGER COMPARTMENT) 14. GASPER ASSEMBLY COCKPIT
7. VENT AIR SUPPLY PLENUM 15. BULKHEAD PLENUM ASSEMBLY
8. DOOR PILLAR PLENUM
Figure 201. Vent System
Page 202
Original 21-20-00
2. Water Separator Assembly (5). Install flexible duct (5) to water

A. Water Separator Assembly Removal separator assembly and secure with
hose clamp (4). Torque hose clamp (4).
(Ref. Figure 202)
(1). Opening right forward access door
assembly R155 and transmission access (6). Install flexible duct (2) between inlet
door assembly R210 (Ref. Section and water separator assembly and
06-00-00). secure with hose clamp (1). Torque hose
(2). Remove hose clamp (1) from flexible clamp (1).
duct (2) and water separator assembly
(3). Disconnect flexible duct.
(7). Close right forward access door assem
(3). Remove hose clamp (4) from flexible
bly R155 and transmission access door
duct (5) and disconnect flexible duct
from water separator assembly (3). assembly R210 (Ref. Section 06-00-00).
(4). Carefully remove sealant from junction

of water separator base legs and deck,
if installed.
(5). Remove nuts (6), screws (7) and 18 in-lb
washers (8) and remove water separa 2.0 Nm
tor assembly.
2
B. Water Separator Assembly Installation 4
(Ref. Figure 202)

3
5
Consumable Materials 6
(Ref. CSPSPM) 7
Item Nomenclature
7
C208 Sealing Compound, Fuel Resistant 8
(1). Correctly orient water separator

assembly (3) and align with screw holes 1
or suds on deck.
9
(2). Install screws (7), washers (8) and nuts 18 in-lb 7
2.0 Nm 8
(6). Torque screw (7) and nuts (6).
6
(3). Two washers must be used between
water separator and transmission deck 9G21010
if round head rivets interfere with 1. CLAMP, BAND TYPE
installation of separator. 2. FLEXIBLE DUCT, INLETTOSEPARATOR
3. WATER SEPARATOR ASSEMBLY
Sealing Compound (C208)
4. CLAMP, BAND TYPE
5. FLEXIBLE DUCT, SEPARATORTOFAN
6. NUT
7. SCREW
(4). Apply a fillet of sealing compound 8. WASHER
(C208) at junction of water separator 9. STUD ADHESIVE BONDED
base legs and deck (Ref. CSP-SPM,
Section 20-50-00). Figure 202. Water Separator
Page 203
21-20-00 Original
3. Vent System Fan mounting brackets and deck structure

A. Vent System Fan Removal
(4). Connect ducts (2 and 3) to recirculating
(Ref. Figure 203) fan and secure with hose clamps (1).
Torque clamps (1).
(1). Opening right forward access door
assembly R155 and transmission access (5). Attach electrical connector P513 (9) to
door assembly R210 (Ref. Section recirculating fan.
06-00-00).
(6). Close right-hand forward access door
(2). Detach electrical connector P513 (9). assembly R155 and transmission access
door assembly R210 (Ref. Section
(3). Remove hose clamps (1) securing ducts 06-00-00).
(2 and 3) to recirculating fan.
10 in-lb
(4). Remove screws (5) and washers (6) 1.1 Nm 2
attaching fan to mounting bracket (7
and 8) and remove circulating fan.
1
20 - 25 in-lb
B. Vent System Fan Installation 2.2 - 2.8 Nm
(Ref. Figure 203) 5
9
(Ref. CSPSPM)
Item Nomenclature 4
C205 Sealing Compound 6 8

C205 Sealing Compound
5
(1). Clean and prepare vent recirculating 6
fan mounting bracket for electrical
1
bonding (Ref. CSP-SPM, Section
7
20-50-00).
(2). Install recirculating fan (4) in mounting
3
bracket (7 and 8) with screws (5) and
washers (6). Torque screws (5). 9G21011
1. CLAMP, BAND TYPE
Sealing Compound (C205) 2. FLEXIBLE DUCTTOWATER SEPARATOR
3. DUCT ASSEMBLY ROOF DECK
4. RECIRCULATING FAN
5. SCREW
6. WASHER
7. FAN MOUNTING BRACKET FWD
(3). Remove old sealant and clean faying 8. FAN MOUNTING BRACKET AFT
9. ELECTRICAL CONNECTOR (P513)
surfaces. Apply sealing compound
(C205) to cover faying surfaces between Figure 203. Recirculating Fan
Page 204
Original 21-20-00
7
9 2
1
10
6
5
8
3
7
1
5 7
6
4 9G21009
1. CLAMP, BAND TYPE 6. FLEXIBLE DUCTTOGASPER ASSEMBLY
2. FLEXIBLE DUCT, AFT CABIN 7. GASPER ASSEMBLY PLENUM CAP
3. FLEXIBLE DUCT, FWD CABIN 8. DUCT ASSEMBLY, ROOF DECK
4. PLENUM ASSEMBLY, AIR SUPPLY DUCT 9. SCREW
5. CLAMP, BAND TYPE 10. WASHER
Figure 204. Vent Air Supply Plenum Assembly
4. Vent Air Supply Plenum Assembly (3). Remove hose clamps (1) and disconnect
flexible ducts (2 and 3) from vent air
supply assembly (4).
A. Vent Air Supply Plenum Assembly
Removal (4). Remove clamps (5) and disconnect
plenum assembly flexible ducts (6) from
(Ref. Figure 204) gasper assembly plenum caps (7).
(5). Remove sealant from fasteners on roof
(1). Open left forward access door assembly deck duct assembly (8). Remove screws
L155 (Ref. Section 06-00-00). (9) and washers (10) from roof deck
duct assembly.
(2). Remove cabin compartment interior (6). Remove plenum assembly air supply (4)
roof panels (Ref. Section 25-20-00). from ceiling structure.
Page 205
21-20-00 Original
B. Vent Air Supply Plenum Assembly Sealing Compound (C205)

Installation
(Ref. Figure 204)

(2). Apply sealing compound (C205) to cover
Consumable Materials faying surfaces between duct and deck
(Ref. CSPSPM) structure (Ref. CSP-SPM, Section
Item Nomenclature 20-50-00).
C205 Sealing Compound (3). Connect plenum assembly flexible ducts
(6) to gasper assembly plenum caps (7)
with hose clamps (5). Torque hose
NOTE: If seal between duct assembly and deck clamps (5).
has been broken it is necessary to reseal the
duct assembly. Remove old sealant and (4). Connect flexible ducts (2 and 3) to
clean faying surfaces. Apply sealing com plenum assembly (4) with hose clamps
pound (C205) to faying surfaces and install (1). Torque hose clamps (1).
fasteners.
(5). Install cabin compartment interior roof
panels (Ref. CSP-SPM, Section
(1). Place vent air supply plenum assembly 25-20-00).
(4) in position and install screws (9) and
washers (10) through roof deck duct (6). Close left-hand forward access door
assembly (8). Torque screws (9). assembly L155 (Ref. Section 06-00-00).
Page 206
Original 21-20-00
2
11 10
18
(2 PL)
16
15 12
17 (2 PL) 13
14
(6 PL)
8
3 4
6
7 9
5 9G21013
1. SCREW CROSSED RECESSED, FLAT 10. CLAMP, BAND TYPE

2. SIDE GASPER ASSEMBLY 11. FLEXIBLE DUCT AFT CABIN
3. HOSE CLAMP BAND TYPE 12. GASPER ASSEMBLY PLENUM CAP
4. FLEXIBLE DUCT PLENUMTOGASPER 13. GASPER NUT
5. LH GASPER MOUNTING PLENUM 14. PASSENGER GASPER ASSEMBLY
6. SCREW CROSSED RECESSED, PAN HEAD 15. PLENUM CAP CLAMP
7. WASHER, FLAT 16. CLAMP, BAND TYPE
8. RH GASPER MOUNTING PLENUM 17. DOOR PILLAR PLENUM
9. OVERHEAD GASPER ASSEMBLY 18. TIEDOWN STRAP
Figure 205. Gasper Assemblies
5. Gasper Assembly Crew Station side gasper (2) and remove gasper
assembly.
A. Gasper Assembly (Crew Station)
B. Gasper Assembly (Crew Station)
Removal
Installation
NOTE: This task is typical for left and right
NOTE: This task is typical for left and right crew station gasper installation.
crew station gasper removal.
(1). Install crew station side gasper assem
(1). Remove crew station side gasper bly in door pillar with screws (1).
assembly by removing screws (1) from Torque screws (1).
Page 207
21-20-00 Original
6. Gasper Assembly, Crew Station Overhead 7. Gasper Assembly, Passenger

Compartment
A. Gasper Assembly, Crew Station
(Overhead) Removal A. Gasper Assembly (Passenger
Compartment) Removal
(Ref. Figure 205)
(Ref. Figure 205)
(1). Remove crew compartment interior
center beam main covers (Ref. Section (1). Gain access to gasper assembly by
25-10-00). removing cabin compartment interior
roof panels (Ref. Section 25-20-00).
(2). Remove hose clamp (3) securing duct
(4) to left gasper mounting plenum (5) (2). Remove hose clamp (10) securing
and remove plenum from duct. flexible duct (11) to gasper assembly
plenum cap (12).
(3). Remove screws (6) and washers (7) and
separate left gasper mounting plenum (3). Loosen gasper securing nut (13) and
from right gasper mounting plenum (8). remove gasper assembly (14), plenum
cap (12), plenum cap clamp (15) and
(4). Remove left or right gasper assembly nut from gasper mounting structure.
(9) from mounting plenum.
B. Gasper Assembly (Passenger
B. Gasper Assembly, Crew Station Compartment) Installation
(Overhead) Installation
(Ref. Figure 205)
(Ref. Figure 205)
(1). Place gasper assembly (14) through
(1). Place gasper assembly (9) into left (5) bottom of gasper mounting structure
or right (8) gasper mounting plenum. and install gasper securing nut (13),
gasper assembly plenum cap (12) and
(2). Mate left and right gasper mounting plenum cap clamp (15). Tighten gasper
plenums together and install screws (6) securing nut (13) to ensure no axial
and washers (7). Torque screws (6). movement.
(3). Install gasper mounting plenum in duct (2). Connect flexible duct (11) to gasper
(4) and secure with hose clamp (3). assembly plenum cap with hose clamp
Torque clamp (3). (10). Torque hose clamp (10).
(4). Install crew compartment interior (3). Close access to gasper by installing
center beam main covers (Ref. Section cabin compartment interior roof panels
25-10-00). (Ref. Section 25-20-00).
Page 208
Original 21-20-00
Section
214000
Heat / Defog System
HEAT / DEFOG SYSTEM

1. Heat / Defog System A. Engine Bleed Air Check Valve
The heat/defog system supplies heated air to The engine bleed air check valve is an in-line
the cabin and crew area, and provides heated check valve that prevents reverse flow of bleed
air for defog purposes. Compressor bleed air air into the engine compressor of a failed
from both engines is used for heat and defog. engine. The bleed air check valve attaches to
the bleed air fitting.
In case of an engine failure the heat/defog is
automatically shutoff through the Integrated B. Flow Control Shutoff Valve
Instrument System (IIDS). The heat/defog can
be reactivated by placing the CAB HEAT The flow control shutoff valve is a normally
switch on the center console utility panel to closed solenoid valve constructed of stainless
the OVRD position. When a fire/overheat steel. The valve is located at the intersection of
bleed air leak indication CAB HEAT appears the compressor bleed air lines from both
on the IIDS, the IIDS will automatically engines. The valve is electrically activated by
shutoff the heat/defog system. The heat/defog the pilot to control the flow of compressor bleed
system consists of: air to the heat/defog system.
Engine Bleed Air Check Valve - Prevents C. Heat Flow Control Valve
reverse flow of bleed air. The heat flow control valve is a stainless steel
Flow Control Shutoff Valve - Provides crew single ball valve. The valve is located on the
member control of bleed air to the heat/defog aft cabin heat ejector. The valve is activated
system. mechanically for controlling the flow of bleed
air entering into the aft cabin heater ejector.
Heat Flow Control Valve - Controls the flow
of bleed air to the aft cabin heater ejector. D. Heater Control Cable
The heater control cable is located in the aft
Heater Control Cable - Mechanically
passenger compartment. The cable is a push
controls heat flow control valve position.
pull cable constructed of stainless steel. The
Aft Cabin Heater Ejector - Mixes bleed air cable adjusts the heat flow control valve.
with ambient cabin air and releases the mixed
E. Aft Cabin Heat Ejector
air to the cabin compartment.
The aft cabin heater ejector is located in the
Heat/Defog Bleed Air Lines - Routes bleed
aft passenger compartment. The ejector acts
air to the flow control valves.
like a flow divider mixing inside ambient cabin
Heat/Defog Valve - Controls the flow of bleed air with hot engine bleed air to produce heated
air to the heat/defog ejector. cabin air.
Heat/Defog Control Cable - Controls heat F. Heat / Defog Bleed Air Tubes
defog valve position. The heat/defog bleed air tubes are stainless
Heat/Defog Ejector - Mixes ambient cockpit steel tubes that route bleed air throughout the
air with bleed air. heat/defog subsystem. The tubes route bleed
air to the heat flow control valve, heat/defog
Defog Manifolds - Releases heated air to the valve, and foot heater valves.
wind screens for defog purposes.
G. Heat / Defog Valve
Foot Heater Valve - Releases heated air to
the crew compartment. The heat/defog valve is a stainless steel ball
valve located at the lower left cockpit fuselage
Foot Heater Control Cable - Controls foot section. The valve is mechanically activated to
heater valve position. route bleed air into the heat/defog ejector for
Page 1
21-40-00 Original
distribution to the defog manifold and foot heat/defog ejector to the heat/defog manifolds
heater valves. and foot heaters.
H. Heat / Defog Control Cable K. Defog Manifolds

The defog manifolds are located below the
The heat/defog control cable is a push pull cockpit wind screens. The defog manifolds are
cable constructed of stainless steel. The cable constructed of composite material. The defog
is located on the center console. The cable manifold allows heated air to blow against the
adjusts the heat/defog valve that controls pilot and copilot wind screens for defog
bleed air flow entering into the heat/defog purposes.
ejector for distribution to the defog manifold
and foot heater valves. L. Foot Heater Control Cable
I. Heat / Defog Ejector The foot heater control cables are push pull
stainless steel cables. The two control cables
The heat/defog ejector is located below the are located under the instrument panel. Each
crew compartment floor near the aircraft foot heater control cable operates a butterfly
centerline. The ejector acts like a flow divider valve, which allows the pilot/copilot to adjust
mixing inside ambient air with hot engine heated air outflow.
bleed air to produce heated crew/defog air. M. Foot Heater Valves
J. Plenum Heat / Defog Hoses The foot heater valves are mounted on the side
of the forward battery compartment, directed
The plenum heat/defog hoses are flexible towards the pilots feet. The foot heater valves
silicon rubber coated woven fiberglass hose are constructed of composite material with an
with a nylon helical reinforcement. Located in internal aluminum butterfly disc. The foot
the lower left and right cockpit fuselage heater valve allows for a varying amount of
section, the hoses route bleed air from the heated air to blow onto the pilot/copilot feet.
Page 2
ENGINE BLEED
AIR HOSES
ENGINE BLEED
AIR CHECK VALVE
FLOW CONTROL
SHUTOFF VALVE
ENGINE DECK FITTING MAIN BLEED

FITTING
ENGINE BLEED
AIR CHECK VALVE
FLEXIBLE HEATER
CONTROL CABLE
HEATING SYSTEM FLOW

CONTROL VALVE SINGLE BALL
AFT CABIN
HEAT EJECTOR
DEFOG
MANIFOLD
FOOT HEATER
CONTROL CABLE
FOOT HEATER
VALVE
BLEED AIR TUBING
HEAT/DEFOG
CONTROL CABLE
HEAT/DEFOG HEAT/DEFOG VALVE

EJECTOR
HEAT/DEFOG PLENUM HOSE
9G21016A
Figure 1. Heat / Defog System
Page 3
21-40-00 Original
CHECK
VALVES
ENGINE ENGINE
PASSENGER COMPARTMENT
FLOW CONTROL
VALVE
STARTUP
LOCK OUT
HEAT ON/OFF PASSENGER

SWITCH COMPARTMENT
EJECTOR
FLOW CONTROL
FLOW CONTROL VALVE
SHUTOFF VALVE
(ON/OFF) DEFOGGING
MANIFOLDS
PILOT HEAT
EJECTOR
FOOT
HEATER
FOOT HEATER
CONTROL VALVE
CREW STATION 9G21022
Figure 2. Heat / Defog System Schematic
Page 4
Original 21-40-00
HEAT / DEFOG SYSTEM

FAULT ISOLATION
1. Heat / Defog System Troubleshooting Troubleshooting tables should be used with
manual.
brief summary of heat/defog system faults in the Rotorcraft Maintenance Manual
which may be encountered (Ref. Table 101). CSP-900RMM-2 (Ref. Section 98-40-00).
Table 101. Heat / Defog System Troubleshooting
Bleed air on with heat/defog Defective wiring circuit Test and repair wiring circuit. 206000
switch OFF between flow control shutoff
valve and utility control
panel.
Flow control shutoff valve Remove and replace flow 214000
stuck open. control shutoff valve.
No heat/defog bleed air with Defective wiring circuit Test and repair wiring circuit. 206000
switch set to ON position. between circuit breaker and
flow control shutoff valve.
Fire/overheat bleed air leak Find heat/defog bleed air leak 214010
detection system shut down and repair leak. 261010
heat/defog system through
IIDS.
(See Note)
Defective flow control shutoff Remove and replace flow 214000
valve. control shutoff valve.
No cabin heat with switch set Ejector control cable(s) Adjust control cable for proper 214000
to ON. assembly disconnected, out rigging. Replace broken cable.
of rig, or broken cable.
Ejector produces excessive Internal ejector failure. Replace heat ejector. 214000
amounts of hot air.
Whistle sound from under Bleed air coupling(s) or Turn off HEAT switch for 214000
cabin floor with heat/defog tube(s) leaking. (Bleed air heat/defog system, if sound
ON. (No system shutdown by leak not hitting detection stops; repair coupling(s) or
IIDS and IIDS does not cable to cause IIDS replace leaking air tube.
display CAB HEAT Warning). indication.)
Page 101
Table 101. Heat / Defog System Troubleshooting (Cont.)

CAB HEAT illuminates HEAT switch is in the OVRD Place HEAT switch to OFF 214000
(RED) on IIDS Caution/Warn- position. position.
ing panel when heat/defog
system is operating and does
not automatically shut off
bleed air.
NOTES:
(1) The IIDS automatically disables heat/defog in the event of fire/overheat bleed air leak indication. IIDS
illuminates CAB HEAT on Caution/Warning IIDS panel, interrupts electrical ground of flow control shutoff
valve through the IIDS.
Page 102
Original 21-40-00
A612 FWD INTERCONNECT PANEL W122

TB2-1 J3 P170
A B C D 92 E GS102-K
N P R S
W123 A2
IIDS
TB4-5 J1 P171
P102 J2
J K L M 19 34 HEAT/DEFOG INSTALLED
A606 W124
UTILITY CONTROL PANEL
P172 J6
J1 P117 P104 J4
J 22 7 ZJ HEAT ON/OFF
S2
CAB HEAT
SWITCH
1 OFF
2
A699
3 ON FLOW CONTROL SHUTOFF
W124 W311
A601 900 CONFIG VALVE
OFF CIRCUIT BREAKER PANEL J520 P520
4
TB302-2
5 CB12 J2 P128 (WHITE WIRE)
BLD AIR A C
6 HEAT
28VDC 13 B
OVRD 5A
C
(BLUE WIRE)
D D
K E
B E GS104-C F
A601 902 CONFIG
CIRCUIT BREAKER PANEL
CB36 J2 P128
BLD AIR
HEAT
R. DC BUS 13
5A
9G21023B
Figure 101. Heat / Defog System Wiring Diagram
Page 103
21-40-00 Original
9G21-033
Figure 102. Utility Control Panel (Heat / Defog)
Page 104
Original 21-40-00
HEAT/DEFOG SYSTEM
REMOVAL/INSTALLATION
1. Heat/Defog Ejector B. Heat/Defog Ejector Installation
(Ref. Figure 401)
A. Heat/Defog Ejector Removal
(Ref. Figure 401) Consumable Materials

(Ref. CSPSPM)
Item Nomenclature
(1). Open landing light window panel N82,
panel N106 and center access panel C801 Foam (900 CONFIG)
B142 (Ref. Section 06-00-00). C709 Tape, Adhesive (900 CONFIG)
C610 Rubber, Expanded (902 CONFIG)
NOTE: Avoid damage to insulation during re C710 Tape, Glass Fabric (902 CONFIG)
moval if possible. Reuse insulation upon
installation.
(1). Attach heat/defog ejector to structure
with screws, washers and nuts. Torque
(2). Remove and discard tape (19) and nuts.
remove insulation (18) from tube
connections. (2). Install heat/defog plenum sleeve to
heat/defog ejector and install clamp.
(3). 900 CONFIG - Disconnect threadless Torque hose clamp.
flexible coupling assembly (16) and
(3). 900 CONFIG - Install threadless
retainer (6) from heat/defog ejector (7)
flexible coupling seal with cup facing
and heat/defog valve (5).
tube end (Ref. Section 21-40-00).
(4). 900 CONFIG - Retain spacer fitting (4). 900 CONFIG - Install spacer fitting,
(17), remove and discard seal(s) (15) connecting heat/defog ejector to
from heat/defog ejector (7). heat/defog valve with retainer and
flexible coupling.
(5). 902 CONFIG - Disconnect coupling (5). 902 CONFIG - Connect coupling nut to
nut (22) from heat/defog ejector (7) and heat/defog ejector and heat/defog valve.
heat/defog valve (5).
NOTE: Wrap tube connections with insulation
(6). Remove clamp (20) and disconnect and tape. Overlap the existing insulation on
heat/defog plenum sleeve (21) from tube and line assemblies one inch.
heat/defog ejector.
(6). Install insulation (18) over tube
connections and wrap with tape (19).
(7). Remove screws (12), nuts (14) and
washers (13) from tangs attaching (7). Close landing light window panel N82,
heat/defog ejector to structure and panel N106 and center access panel
remove ejector. B142 (Ref. Section 06-00-00).
Page 401
21-40-00 Original
2. Heat/Defog Valve B. Heat/Defog Valve Installation

A. Heat/Defog Valve Removal (Ref. Figure 401)
(Ref. Figure 401)
(1). Open landing light window panel N82, (Ref. CSPSPM)
panel N106 and center access panel Item Nomenclature
B142 (Ref. Section 06-00-00). C801 Foam (900 CONFIG)
(2). Remove cotter pin (1), washers (2) and C709 Tape, Adhesive (900 CONFIG)
clevis pin (4) and disconnect heat/defog C610 Rubber, Expanded (902 CONFIG)
control cable clevis (3) from heat/defog C710 Tape, Glass Fabric (902 CONFIG)
valve (5).
NOTE: Avoid damage to insulation during re (1). 900 CONFIG - Install threadless
moval if possible. Reuse insulation on flexible coupling seal with cup facing
installation. tube end (Ref. Section 21-40-00).
(3). Remove and discard tape (19) and (2). 900 CONFIG - Install spacer fitting,
remove insulation (18) from heat/defog connecting heat/defog valve to heat/de
tube assembly (11) and heat/defog valve fog ejector with retainer and flexible
(5). coupling.
(4). 900 CONFIG - Disconnect flexible (3). 902 CONFIG - Install coupling nut,
coupling assembly (16) and retainer (6) connecting heat/defog valve to heat/de
from heat/defog valve to heat/defog fog ejector. Torque nut.
tube assembly.
(4). 900 CONFIG - Connect heat/defog
(5). 900 CONFIG - Remove and discard valve to heat/defog tube assembly with
seal(s) (15) from heat/defog valve (5) retainer and flexible coupling.
and heat/defog tube assembly (11).
(5). 902 CONFIG - Connect heat/defog
(6). 900 CONFIG - Disconnect flexible valve to heat/defog tube assembly
coupling assembly (16) and retainer (6) coupling nut. Torque nut.
from heat/defog valve to heat/defog
ejector (7) and remove valve. NOTE: Wrap tube connections with insulation
and tape. Overlap the existing insulation on
(7). 900 CONFIG - Remove and discard tube and line assemblies one inch.
seal(s) (15) from heat/defog valve (5)
and heat/defog ejector (7), retain spacer (6). Install insulation (18) over tube
fitting (17). connections and wrap with tape (19).
(8). 902 CONFIG - Disconnect coupling (7). Connect heat/defog control cable to
nut (22) from heat/defog valve to heat/defog valve with clevis pin,
heat/defog tube assembly. washers and cotter pin.
(9). 902 CONFIG - Disconnect coupling (8). Close landing light window panels N82,
nut (22) from heat/defog valve-to-heat/ panel N106 and center access panel
defog ejector (7) and remove valve. B142 (Ref. Section 06-00-00).
Page 402
Original 21-40-00
3. Heat/Defog Control Cable (2). Install cable through cable mounting

bracket and install lower washers and
A. Heat/Defog Control Cable Removal jam nuts on lower threaded area
(Ref. Figure 401) heat/defog cable.
(1). Open landing light window panel N82, (3). Upper threaded area to be approxi
nose access panel N106 and bottom mately two inch above mounting
center access panel assembly B142 bracket. Tighten jam nuts by hand. Do
(Ref. Section 06-00-00). not torque jam nuts at this time.
(2). Remove cotter pin (1), washers (2) and (4). Insert cable through hole in cockpit
clevis pin (4) and disconnect heat/defog floor and through bulkhead web.
control cable (3) from heat/defog valve (5). Loosely install jam nuts and washers
(5). on opposite end lower threaded area of
(3). Remove jam nut (8) and washer (9) control cable on forward side of bulk
from lower threaded area of heat/defog head web.
control cable. (6). Connect control cable to heat/defog
(4). Remove jam nut (8) and washer (9) valve with clevis pin, washers and
from upper and lower threaded areas cotter pin.
and remove control cable from cable (7). Adjust cable linkage as required to
mounting bracket (10) and pull cable ensure proper valve closure. Adjust
through bulkhead web, cockpit floor cable so that heat/defog valve arm
and mounting bracket. contacts stop in both the fully closed
B. Heat/Defog Control Cable Installation and open position. Torque jam nuts.
(Ref. Figure 401) (8). Close landing light window panel N82,
nose access panel N106 and bottom
(1). Install jam nut and washer on upper center access panel B142 (Ref. Section
heat/defog control cable. 06-00-00).
Page 403
21-40-00 Original
15
16
6
8
15
900 CONFIG 9
11
12 10
13
14
95-110 in-lb
7 8
10.7-12.4 Nm
5
11
9
460-500 in-lb
57.96-56.48 Nm 22 (2 PL)
AN FLARED FITTINGS
902 CONFIG
95-110 in-lb 9
20 10.7-12.4 Nm 8
18
21
18 in-lb 19
2.0 Nm
1 2
3
15
5
4 16
900 CONFIG
6
17
15
9G21017B
1. COTTER PIN 13. WASHER

2. WASHER 14. NUTS
3. HEAT/DEFOG CONTROL CABLE (CLEVIS END) 15. SEAL
4. CLEVIS PIN 16. FLEXIBLE (THREADLESS) COUPLING
5. HEAT/DEFOG VALVE 17. SPACER FITTING 0.875 INCH
6. RETAINER 18. FOAM (C801)(900 CONFIG)RUBBER (C610)(902
7. HEAT/DEFOG EJECTOR CONFIG)
8. JAM NUT 19. ADHESIVE TAPE (C709)(900 CONFIG)GLASS FABRIC
9. WASHER TAPE (C710)(902 CONFIG)
10. MOUNTING BRACKET 20. HOSE CLAMP BAND TYPE
11. HEAT/DEFOG TUBE ASSEMBLY 21. SLEEVE (FIBERGLASS, RUBBER, SILICONE)
12. SCREW 22. NUT, TUBE COUPLING
Figure 401. Heat/Defog Valve, Ejector, and Control Cable
Page 404
Original 21-40-00
4. Defog Manifold (4). Connect defog manifold to heat/defog

plenum to outlet hose with hose clamp.
A. Defog Manifold Removal Torque hose clamp.
(Ref. Figure 402)
5. Foot Heater Valve
NOTE: This task is typical for left or right De
fog Manifold removal. A. Foot Heater Valve Removal
(1). Remove hose clamp (3) and disconnect (Ref. Figure 402)
defog manifold (1) from heat/defog
plenum to outlet hose (2). NOTE: This task is typical for left or right Foot
(2). Remove nuts (4), washers (5), and Heater Valve removal.
screw (6).
(1). Disconnect foot heater cable (8) from
(3). Remove nuts (4) and washers (5) from foot heater valve (7).
stud and remove defog manifold.
(2). Remove screws (10) and washers (11)
B. Defog Manifold Installation attaching foot heater valve to bracket.
(Ref. Figure 402)
(3). Loosen hose clamp (9) and remove foot
heater valve from heat/defog plenum to
Consumable Materials outlet hose (2).
(Ref. CSPSPM)
Item Nomenclature B. Foot Heater Valve Installation
(Ref. Figure 402)
NOTE: This task is typical for left or right De NOTE: This task is typical for left or right Foot
fog Manifold installation. Heater Valve installation.
(1). Install defog manifold with nuts, (1). Install foot heater valve in heat/defog
washer, and screw. Torque nuts. plenum to outlet hose. Install hose
(2). Install nuts and washers on mounting clamp. Torque hose clamp.
stud. Torque nut.
(2). Install screws and washers through
Sealing Compound (C205) bracket into foot heater valve. Torque
screws.
(3). Connect foot heater cable to valve and

adjust linkage as required to ensure
(3). Seal stud fasteners with sealing proper closure. Adjust cable so that the
compound (C205) (Ref. Section foot heater valve arm contacts stop in
20-50-00). the fully closed position.
Page 405
21-40-00 Original
6. Foot Heater Cable

4
4 5
5 15 6
13
14
1
18 in-lb 15
9 2.0 Nm
95-110 in-lb 13
10.7-12.4 Nm 14
16 8
18 in-lb 11
3 2.0 Nm
10
2 12
9G21014
1. DEFOG MANIFOLD 9. HOSE CLAMP, BAND TYPE

2. HEAT/DEFOG PLENUM OUTLET HOSE 10. SCREW
3. HOSE CLAMP, BAND TYPE 11. WASHER
4. NUT 12. SUPPORT BRACKET
5. WASHER 13. JAM NUT
6. SCREW 14. WASHER
7. FOOT HEATER VALVE 15. CABLE MOUNTING BRACKET
8. FOOT HEATER CABLE 16. CABLE MOUNTING BRACKET
Figure 402. Defog Manifold, Foot Heater Valve, Control Cable
A. Foot Heater Cable Removal B. Foot Heater Cable Installation
NOTE: This task is typical for left or right Foot

NOTE: This task is typical for left or right Foot Heater Cable installation.
Heater Cable removal.
(1). Install foot heater cable through cable
(1). Disconnect foot heater cable (8) from mounting bracket and install washer
foot heater valve (7). and jam nut.
(2). Insert notch in cable into slot in cable

(2). Loosen jam nuts on foot heater cable bracket. Torque jam nuts.
remove cable from slot in cable bracket
(16). (3). Connect foot heater cable to foot heater
valve and adjust linkage as required to
(3). Remove jam nut (13) and washer (14) ensure proper closure. Adjust cable so
from foot heater cable and remove cable that the foot heater valve arm contacts
through cable mounting bracket (15). stop in the fully closed position.
Page 406
Original 21-40-00
7. Aft Cabin Heat Ejector B. Aft Cabin Heat Ejector Installation
A. Aft Cabin Heat Ejector Removal (Ref. Figure 403)

(Ref. CSPSPM)
(1). Remove aft cabin seats assembly, if Item Nomenclature
applicable (Ref. Section 25-20-00). C801 Foam (900 CONFIG)
C709 Tape, Adhesive (900 CONFIG)
(2). Remove right-hand baggage compart
ment interior trim insulation panel
(Ref. Section 25-50-00). C710 Tape, Glass Fabric (902 CONFIG)
(3). Remove guard (32) from lower ejector (1). Install screws and washers through
screen. Guard is attached with hook fuselage frame into ejector mounting
and pile tape. bracket. Torque screws. Position ejector
as far inboard as possible.
(4). Remove screws (19), washers (20),
ejector screen (17) and ejector gasket (2). Install screw washer spacers and
(18) from interior panel. Two places. cushioned support clamp to cabin heat
ejector and composite standoff.
(5). Remove cabin interior trim panel (3). 900 CONFIG - Install threadless
adjacent to ejector outlet (Ref. Section flexible coupling seal with cup facing
25-20-00). tube end (Ref. Section 21-40-00).
NOTE: Avoid damage to insulation during re (4). 900 CONFIG - Install spacer fitting,
moval if possible. Reuse foam on installa connecting cabin heat ejector to heating
tion. system flow control valve with retainer
and flexible coupling assembly.
(6). Remove and discard tape (7,) and
(5). 902 CONFIG - Install coupling nut,
remove insulation (6) from connections
connecting cabin heat ejector to heating
(8).
system flow control valve. Torque nut.
(7). Remove screw (30), washer (26), spacer NOTE: Wrap tube connections with insulation
(31), cushioned support clamp (27) from and tape. Overlap the existing insulation on
aft cabin heat ejector (22) and compos tube and line assemblies one inch.
ite standoff (29).
(6). Install insulation (6) over tube connec
(8). 900 CONFIG - Disconnect flexible tions and wrap with tape (7).
coupling assembly (8) and retainer (9) (7). Position ejector gaskets, between
from heating system flow control valve ejector outlets and interior trim and
(5) and aft cabin heat ejector (22). install ejector screen, screws and
washers through interior trim panel
(9). 900 CONFIG - Retain spacer fitting into ejector. Torque screws.
(11), remove and discard seals (10) from
cabin heat ejector. (8). Install cabin compartment right side
wall interior trim insulation panel
(10). 902 CONFIG - Disconnect coupling adjacent to ejector outlet (Ref. Section
nut (33) from heating system flow 25-20-00).
control valve (5) and aft cabin heat (9). Install baggage compartment interior
ejector (22). trim insulation panels (Ref. Section
25-50-00).
from fuselage frame and remove aft (10). Install cabin seats assembly, if applica
cabin heat ejector. ble (Ref. Section 25-20-00).
Page 407
21-40-00 Original
8. Heating System Flow Control Valve Single (2). Put flow control valve in its installed
Ball position.
A. Heating System Flow Control Valve (3). 900 CONFIG - Install flexible coupling
Single Ball Removal assemblies, spacers, and retainers on
flow control valve.
(Ref. Figure 403)
(4). 902 CONFIG - Connect coupling nuts
(1). If necessary, remove cabin seats to flow control valve. Torque nuts.
assembly (Ref. Chapter 25-20-00). NOTE: Wrap tube connections with insulation
(2). Remove right aft cabin compartment and tape. Overlap insulation on tube and
interior trim insulation panel adjacent line assemblies one inch.
to aft cabin heat ejector outlet (Ref. (5). Install insulation on tube connections
Section 25-20-00). and wrap with tape.
(3). Remove cotter pin (1), washers (2), and (6). Connect control cable to flow control
clevis pin (3). valve with clevis pin, washers, and
cotter pin.
NOTE: If possible, prevent damage to insula
tion. You can use insulation again. (7). If necessary, adjust cable until flow
control valve arm touches stop in both
(4). Remove and discard tape (7) and the fully closed and fully open position.
remove insulation (6) from tube
connections. (8). Install right cabin compartment
interior trim panel adjacent to aft cabin
(5). 900 CONFIG - Disconnect flexible heat ejector outlet (Ref. Section
coupling assemblies (8) and retainers 25-20-00).
(9) from flow control valve (5). Remove (9). Install cabin seats assembly, if applica
flow control valve. ble (Ref. Section 25-20-00).
(6). 900 CONFIG - Keep spacer fitting(s) 9. Flexible Heater Control Cable Assembly
(11). Remove and discard seals (10).
A. Flexible Heater Control Cable
(7). 902 CONFIG - Disconnect coupling Assembly Removal
nuts (33) from flow control valve (5).
Remove flow control valve. (Ref. Figure 403)
(1). If necessary, remove cabin seats
B. Heating System Flow Control Valve
assembly (Ref. Section 25-20-00).
Single Ball Installation
(2). Remove cabin compartment interior
(Ref. Figure 403) trim insulation panel adjacent to
ejector outlet and cabin heat control
Consumable Materials cover plate (Ref. Section 06-00-00.
(Ref. CSPSPM) (3). Remove cotter pin (1), washers (2), and
Item Nomenclature clevis pin (3).
C801 Foam (900 CONFIG)
(4). Remove nuts (23), washers (24), angle
(37), and handle (34).
C710 Tape, Glass Fabric (902 CONFIG) (5). Remove cable plug (35) and washer
(16).
(6). Remove sealing compound from nut
(1). 900 CONFIG - Install threadless
(36) and washer (16).
flexible coupling seal on flow control
valve and tube assemblies (Ref. (7). Pull control cable (4) down and remove
Threadless Flexible Coupling Seal nut (36) and washer (16). Remove
Installation). control cable.
Page 408
B. Flexible Heater Control Cable Torque nuts 20-25 in-lb (2.26-2.82

Assembly Installation Nwm).
(Ref. Figure 403) (6). Adjust cable until flow control valve
arm touches stop in both the fully
Consumable Materials closed and fully open position.
(Ref. CSPSPM)
(7). Tighten cable plug sufficiently to
Item Nomenclature
prevent movement of joint.
(8). Torque nut (15) to apply tension to
cable.
(1). Install control cable, nuts, washers, and
cable plug. Do not tighten at this time. Sealing Compound (C205)
(2). Install nuts, washers, and angle. Do
not tighten at this time.
(3). Connect control cable to flow control
valve with clevis pin, washers, and (9). Apply sealing compound (C205) to
cotter pin. washer and nut (Ref. CSP-SPM).
(4). Install nut and washer on control cable (10). Install cabin compartment interior trim
top end, put control cable through panel adjacent to ejector outlet and
handle and install washer and nut. cabin heat control cover plate.
(5). Adjust nuts until center of handle is (11). If necessary, install cabin seats assemb
0.39 in. (9.91 mm) from end of cable. ly (Ref. Section 25-20-00).
Page 409
3
29
2
27 34
0.39 IN
(9.91 mm)
8 35
26
REF 4 30
23 (2 PL) 31
24 (2 PL)
23 (2 PL)
5 36 24 (2 PL)
16
2
1 8 13 12
4
29 15
28
16
27 14
26 22
25 17
10 20
19
6
32
7
8
18
21
33 (2 PL)
9
11
10
THREADLESS FLEXIBLE COUPLING

TYPICAL INSTALLATION (ROTATED)
900 CONFIG
AN FLARED FITTINGS
902 CONFIG 9G21018B
Figure 403. Cabin Heat Ejector, Single Ball Flow Control Valve, Flexible Heater Control Cable
Page 410

1. COTTER PIN 19. SCREW
2. WASHER 20. WASHER
3. CLEVIS PIN 21. AFT CABIN HEAT TUBE ASSEMBLY
4. CONTROL CABLE 22. AFT CABIN HEAT EJECTOR
5. FLOW CONTROL VALVE 23. NUT
6. FOAM (C801)(900 CONFIG)RUBBER (C610)(902 24. WASHER
CONFIG) 25. SCREW
7. ADHESIVE TAPE (C709)(900 CONFIG) GLASS FABRIC 26. WASHER
TAPE (C710)(902 CONFIG)
27. CUSHIONED SUPPORT CLAMP
8. FLEXIBLE COUPLING ASSEMBLY
28. SPACER
9. RETAINER
29. STANDOFF, COMPOSITE
10. SEAL
11. SPACER FITTING (0.625 INCH) 30. SCREW
12. SCREW 31. SPACER
13. WASHER 32. GUARD
14. EJECTOR MOUNTING BRACKET 33. NUT, TUBE COUPLING
15. NUT 34. HANDLE
16. WASHER 35. CABLE PLUG
17. EJECTOR SCREEN 36. NUT
18. EJECTOR GASKET 37. ANGLE
10. Engine Bleed Air Check Valve (900 Compound, Anti-Seize (C220)
CONFIG)
A. Engine Bleed Air Check Valve Removal
(Ref. Figure 404)
NOTE: This task is typical for left or right en (2). Apply anti-seize compound (C220) to
gine. bleed air fitting and install check valve.
(1). Open L260 or R260 (Ref. Section Torque check valve 500-600 in-lb
06-00-00). (56.5-67.8 Nwm).
(2). Disconnect hose assembly (4) or (5) (3). Apply anti-seize compound (C220)to
from check valve (2). check valve and connect hose to check
(3). Remove check valve (2). valve. Torque coupling nut 500-600
(4). Remove boss seal (3). in-lb (56.5-67.8 Nwm).
B. Engine Bleed Air Check Valve Installation (4). Close L260 or R260 engine cowl (Ref.
(Ref. Figure 404) Section 06-00-00).
(Ref. CSPSPM)
Item Nomenclature
C220 Compound, AntiSeize
NOTE: This task is typical for left or right en

gine.
(1). Install boss seal.
Page 411
11. Flow Control Shutoff Valve Assembly (900 B. Flow Control Shutoff Valve Assembly
CONFIG) Installation
A. Flow Control Shutoff Valve Assembly (Ref. Figure 404)
Removal
(1). Install flexible coupling seals (Ref.
(Ref. Figure 404) Threadless Flexible Coupling Seal
(1). Open R260 (Ref. Section 06-00-00). Installation).
(2). Disconnect electrical connector P520 (2). Put shutoff valve in its installed
(16). position.
(3). Disconnect flexible couplings (13) and (3). Install flexible coupling assemblies,
retainers (12) from shutoff valve (17). spacers, and retainers on shutoff valve.
Remove shutoff valve.
(4). Connect electrical connector P520.
(4). Keep spacer fittings (14). Remove and
discard seals (15). (5). Close R260 (Ref. Section 06-00-00).
Page 412
12. Valve To Deck Tube Assembly (900 B. Valve to Deck Tube Assembly Installation
CONFIG)
(Ref. Figure 404)
A. Valve to Deck Tube Assembly Removal Consumable Materials

(Ref. CSPSPM)
Item Nomenclature
(Ref. Figure 404) C211 Sealing Compound, Corrosion Inhibitive
(1). Open right engine cowl assembly R260 (1). Install new gaskets on top and bottom
(Ref. Section 06-00-00). of engine deck between deck assembly
and tube flanges.
(a). Install bolts in tube assembly flange
(2). Remove baggage compartment interior
through engine deck and flange of
trim roof insulation panel (Ref. Section
tube assembly. Torque bolts.
25-50-00).
(3). Remove right aft station 230.00

interior trim insulation panels (Ref.
Section 25-50-00). (b). Apply sealing compound (C211) to
faying surfaces of tube assembly
flange (19 and 21) (Ref. Section
(4). Remove bolts (22) from deck tube 20-50-00).
assembly (19) flange and engine deck
and tube assembly (21). Remove and (2). Install threadless flexible coupling seals
discard deck gaskets (20) from top and with cup facing tube end (Ref. Section
bottom of engine deck. 21-40-00).
(3). Install spacer fittings, connecting bleed
air flow control shutoff valve to deck
(5). Remove support clamp and attaching
tube assembly with retainer and
hardware from deck line assembly.
flexible coupling.
(4). Install support clamp and attaching
(6). Disconnect flexible coupling (13) and hardware to deck tube assembly.
retainer (12) from deck tube assembly
(19) at bleed air flow control shutoff (5). Install right aft station 230.00 bulk
valve (17). head baggage compartment interior
trim insulation panels (Ref. Section
25-50-00).
(7). Retain spacer fitting (14). Remove and (6). Install baggage compartment interior
discard seals (15) from flow control trim roof insulation panel (Ref. Section
shutoff valve and deck tube assembly. 25-50-00).
(7). Close right engine cowl assembly R260
(8). Remove tube assembly. (Ref. Section 06-00-00).
Page 413
21-40-00 Original
4
9
2 10
11 500 - 600 in-lb
56.5 - 67.8 Nm
8
1 3 5
7
18 6
1 500 - 600 in-lb

2 56.5 - 67.8 Nm
16 6
17
3
15
13
19 15
20 12
22
14
21 15 17
36 - 46 in-lb
4.0 - 5.2 Nm
14 9G21027B
15
1. ENGINE BLEED AIR FITTING 13. THREADLESS FLEXIBLE COUPLING

2. ENGINE BLEED AIR CHECK VALVE 14. SPACER FITTING (0.875 INCH)
3. BOSS SEAL 15. SEAL
4. ENGINE TO VALVE HOSE ASSEMBLY (RH) 16. ELECTRICAL CONNECTOR (P520)
5. ENGINE TO VALVE HOSE ASSEMBLY (LH) 17. BLEED AIR FLOW CONTROL SHUTOFF VALVE
6. HEAT/DEFOG INBOARD FIREWALL TUBE ASSEMBLY 18. TUBE ASSEMBLY FLOW CONTROL SHUTOFF VALVE
7. FITTING FIREWALL TO ENGINE TO FITTING
8. FITTING MAIN BLEED 19. TUBE ASSEMBLY VALVE TO DECK
9. NUT 20. GASKETS
10. FLAT WASHER(S) 21. TUBE ASSEMBLY
11. BOLT 22. BOLT
12. RETAINER
Figure 404. Engine Bleed Air Check Valve/Flow Control Shutoff Valve (900 CONFIG)
Page 414
Original 21-40-00
13. Engine Bleed Air Check Valve (902 (3). Apply anti-seize compound (C220) to
CONFIG) check valve and connect hose to check
valve. Torque coupling nut 500-600
A. Engine Bleed Air Check Valve Removal in-lb (56.5-67.8 Nwm).
(Ref. Figure 405)
(4). Close L260 or R260 (Ref. Section
NOTE: This task is typical for left or right engi 06-00-00).
ne.
14. Flow Control Shutoff Valve Assembly (902
(1). Open L260 or R260 (Ref. Section
CONFIG)
06-00-00).
(2). Disconnect hose (4) or (5). A. Flow Control Shutoff Valve Assembly
Removal
(3). Remove check valve (2).
(Ref. Figure 405)
(4). Remove boss seal (3).
B. Engine Bleed Air Check Valve Installation (1). Open R260 (Ref. Section 06-00-00).
(Ref. Figure 405) (2). Disconnect electrical connector P520

(12).
(3). Disconnect coupling nuts on tubes (14
(Ref. CSPSPM)
and 15). Remove shutoff valve (13).
Item Nomenclature
C220 Compound, AntiSeize B. Flow Control Shutoff Valve Assembly
Installation
NOTE: This task is typical for left or right engi
ne. (Ref. Figure 405)
(1). Install boss seal. (1). Put shutoff valve in its installed
position.
Compound, Anti-Seize (C220)
(2). Connect coupling nuts to shutoff valve.
Torque coupling nuts 500-600 in-lb
(56.5-67.8 Nwm).
(2). Apply anti-seize compound (C220) to (3). Connect electrical connector P520.
bleed air fitting and install check valve.
Torque check valve. (4). Close R260 (Ref. Section 06-00-00).
Page 415
15. Valve To Deck Tube Assembly (902 (6). Remove tube (15).
CONFIG)
B. Valve to Deck Tube Assembly Installation
A. Valve to Deck Tube Assembly Removal
(Ref. Figure 405)
(Ref. Figure 405)
(1). Install tube on valve and bulkhead
(1). Open R260 (Ref. Section 06-00-00). union.
(2). Remove right aft station 230.00 (2). Connect coupling nuts. Torque coupling
bulkhead baggage compartment nuts 500-600 in-lb (56.5-67.8 Nwm).
interior trim insulation panels (Ref. (3). Install clamp.
Section 25-50-00).
(4). Install right aft station 230.00 bulk
(3). Remove baggage compartment interior head baggage compartment interior
trim roof insulation panel (Ref. Section trim insulation panels (Ref. Section
25-50-00). 25-50-00).
(4). Remove clamp from tube (15). (5). Install baggage compartment interior
(5). Disconnect coupling nuts (18) from 25-50-00).
shutoff valve (13) and bulkhead union
(16). (6). Close R260 (Ref. Section 06-00-00).
Page 416
INBOARD FIREWALL
ASSEMBLY
4 REF
14
FS
251.31
12 13
18 (10 PL) 500 - 600 in-lb

56.5 - 67.8 Nm
RH FIREWALL
15
ENGINE DECK
16
10 7 REF
500 - 600 in-lb
4 56.5 - 67.8 Nm 500 - 600 in-lb
VIEW LOOKING INBOARD
19 56.5 - 67.8 Nm
RH SIDE
20 350 - 400 in-lb
21 7 11
39.53 - 45.18 Nm
17 5
9
460 - 500 in-lb 11
51.96 - 56.48 Nm
FS 3
6
248.97
BL
10 0.00 2
RBL
11.78
8
500 - 600 in-lb
500 - 600 in-lb 1
2 56.5 - 67.8 Nm
56.5 - 67.8 Nm 3 1
VIEW LOOKING DOWN 9G21036
Figure 405. Engine Bleed Air Check Valve / Flow Control Shutoff Valve (902 CONFIG)
Page 417
21-40-00 Original

1. ENGINE BLEED AIR FITTING 12. ELECTRICAL CONNECTOR (P520)
2. ENGINE BLEED AIR CHECK VALVE 13. BLEED AIR FLOW CONTROL SHUTOFF VALVE
3. BOSS SEAL 14. TUBE ASSEMBLY FLOW CONTROL SHUTOFF VALVE
4. ENGINE TO VALVE HOSE ASSEMBLY (RH) TO FITTING
5. ENGINE TO VALVE HOSE ASSEMBLY (LH) 15. TUBE ASSEMBLY VALVE TO DECK
6. HEAT/DEFOG INBOARD FIREWALL TUBE ASSEMBLY 16. UNION FLARED BULKHEAD
7. NUT, BULKHEAD UNIVERSAL FITTING 17. TUBE ASSEMBLY
8. FITTING MAIN BLEED 18. NUT, TUBE COUPLING, CRES
9. FITTING FIREWALL TO ENGINE 19. NUT, TUBE COUPLING, ALUMINUM
10. FLAT WASHER 20. FLEXIBLE CELLULAR MATERIAL, EXPANDED RUBBER
11. ELBOW ASSEMBLY, 90 DEG 21. TAPE, GLASS FABRIC, ALUMINIZED
Page 418
Original 21-40-00
16. Threadless Flexible Coupling Seal A. Threadless Flexible Coupling Seal

Assembly (900 CONFIG) Installation
(1). Install seal (5) on tool body (2, T703 or
(Ref. Figure 406) T703-1), with seal cup end facing
tapered end on tool body.
Special Tools (2). Insert tool body (2) into tube end,
(Ref. CSPSPM) carefully slide seal assembly for flexible
Item Nomenclature coupling onto tube end using tool sleeve
(3).
T703 Assembly Tool
T7031 Assembly Tool (3). Using seal reforming tool (4, T703-2 or
T703-3), install over tube end and seal.
T7032 Reforming Tool Assembly
T7033 Reforming Tool Assembly (4). Push in and turn seal reforming tool (4)
until seal bottoms tapered end of
reforming tool.
NOTE: Tool is an aid for seal installation, but (5). Ensure seal is not damage after
not required for installation of seal. installation.
4
1
(REF. TUBE END)

(REF. TUBE END)
9G21032
1. SEAL ASSEMBLY TOOL 4. SEAL REFORMING TOOL ASSEMBLY
2. SEAL ASSEMBLY TOOL BODY 5. SEAL ASSEMBLY FOR FLEXIBLE COUPLING
3. SEAL ASSEMBLY TOOL SLEEVE
Figure 406. Threadless Flexible Coupling Seal Replacement (900 CONFIG)
Page 419
21-40-00 Original
17. Heat/Defog Tube Assembly B. Heat/Defog Tube Assembly Installation
A. Heat/Defog Tube Assembly Removal (Ref. Figure 407)

NOTE: This task is typical for tubes in the
(Ref. Figure 407) heat/defog bleed air system installation.
NOTE: This task is typical for tubes in the
heat/defog bleed air system. Consumable Materials
(Ref. CSPSPM)
(1). Remove right crew seat, and passenger Item Nomenclature
seats (Ref. Section 25-00-00). C801 Foam (900 CONFIG)
(2). Remove carpet from cabin floor, if C610 Rubber, Expanded (902 CONFIG)
applicable. C710 Tape, Glass Fabric (902 CONFIG)
(3). Remove cabin floor panels; AR129,
AR138, A160, AR165, 170, A217, A235 (1). 900 CONFIG - Install threadless
and AR250 as required (Ref. Section flexible coupling seals with the cup
52-20-00). facing tube end (Ref. Section
21-40-00).
(4). Remove bleed air leak detection cable
(Ref. Section 26-10-10). (2). 900 CONFIG - Install tube assemblies
with retainer and flexible coupling.
(5). Remove oxygen hose clamp(s) (1) from (3). 902 CONFIG - Install coupling nuts
inside shield (3) and outside shield (2) and torque coupling nuts.
and carefully remove shielding.
(4). Install tube support clamp with screw,
NOTE: Avoid damage to insulation during re washers and nut. Torque nut.
moval if possible. Reuse insulation on
installation. (5). Wrap tube connections coupling
assembly with insulation (12) and tape
(6). 900 CONFIG - Remove tape (13) and (13) around tube support clamp and
insulation (12) from flexible coupling coupling assembly. Overlap the existing
assembly (14). insulation on tube assemblies one inch.
Do not overlap at Sta. 180.25 and Sta.
(7). 902 CONFIG - Remove tape (13) and 204.50 tube connection. Butt insulation
foam (12) from flared union and and tape against existing insulation to
coupling nuts (27). allow for installation of heat/defog
inside shielding and outside shielding.
(8). Remove screws (18), washers (19) and (6). Install inside shield and outside shield
nut (20) and remove tube support with clamps.
clamps (17).
(7). Install bleed air leak detection system
(9). 900 CONFIG - Remove flexible cable (Ref. Section 26-10-10).
coupling (14), retainer (15) and remove
tube assemblies (21). (8). Install cabin floor panels; AR129,
AR138, A160, A170, A217, A170, A235
(10). 900 CONFIG - Remove and discard and AR250 as required in removal (Ref.
seals (16) from tube assemblies. Section 53-20-00).
(9). Install carpet from cabin floor, if
(11). 902 CONFIG - Loosen coupling nuts applicable.
(27), on tube assemblies (21).
(10). Install crew seat, and passenger seats
(12). Remove tube assembly. (Ref. Section 25-00-00).
Page 420
Original 21-40-00
NOTES:
1. APPLY ANTI-SEIZE COMPOUND MIL-T-8348
TO BULKHEAD FITTING.
2. APPLY GREEN PRIMER (C309) TO FAYING SURFACE

BETWEEN CLAMP AND BRACKET BEFORE INSTALLATION.
3. WRAP ALL TUBE CONNECTIONS AND CLAMP AREAS 16

WITH FOAM AND TAPE EXCEPT TUBES AND VALVES
LOCATED IN ENGINE AREA.
4. WRAP TUBE CONNECTIONS WITH FOAM AND TAPE. OVERLAP

THE EXISTING INSULATION ON TUBE ASSEMBLIES ONE INCH.
DO NOT OVERLAP AT STA. 180.25 AND STA. 204.50 TUBE CONNECTION. 14
BUTT FOAM INSULATION AND TAPE AGAINST EXISTING INSULATION
TO ALLOW FOR INSTALLATION OF HEAT/DEFOG INSIDE AND
OUTSIDE.SHIELDING
15
5. CLAMPS TO BE INSTALLED APPROXIMATELY WHERE SHOWN. 16
9
11
7 FLEXIBLE COUPLING ASSEMBLY

10 TYPICAL INSTALLATION
NOTE 5 5 ( 21 PL NOTE 3, 4 ROTATED)
(TYPICAL 8 900 CONFIG
3
17 PL)
1
460 - 500 in-lb
51.96 - 56.48 Nm
27
6
4
2 17
18
AN UNION CONNECTION
19
TYPICAL INSTALLATION
20
(21 PL NOTE 3, 4, ROTATED)
902 CONFIG
STA 180.25 & 204.50

NOTE 2, 3, 4 9G210311C
Figure 407. Heat/Defog Tube Assembly Replacement (Sheet 1 of 2)
Page 421
21-40-00 Original
18 17
13 19 12
20
18
19 (2 PL)
20
17
21
12 21
NOTE 3 NOTE 2
TYPICAL INSTALLATION OF INSULATION
AND TAPE AT TUBE CONNECTION
24 (2 PL)
25
23 (2 PL)
NOTE 2
12
900 CONFIG
NOTE 1, 3 12
13
902 CONFIG
12 21
13
12
STA.230.50 13 902 CONFIG
NOTE 3
26
NOTE 3 22 900 CONFIG 9G210312A
Figure 407. Heat/Defog Tube Assembly Replacement (Sheet 2 of 2)
Page 422
Original 21-40-00

1. OXYGEN HOSE CLAMP 14. FLEXIBLE COUPLING ASSEMBLY
2. INSIDE SHIELD FORWARD 15. RETAINER
3. OUTSIDE SHIELD FORWARD 16. SEAL
4. INSIDE SHIELD STA. 166 17. CUSHIONED SUPPORT CLAMP
5. OUTSIDE SHIELD STA. 166 18. SCREW
6. INSIDE SHIELD MID 19. WASHER
7. OUTSIDE SHIELD MID
20. NUT
8. INSIDE SHIELD AFT
21. TUBE ASSEMBLY
9. OUTSIDE SHIELD AFT
10. INSIDE SHIELD VERTICAL 22. AIR TEE ASSEMBLY
11. OUTSIDE SHIELD VERTICAL 23. BULKHEAD BODY FITTING
12. FOAM (C801)(900 CONFIG)RUBBER (C610)(902 24. WASHER (TEFLON)
CONFIG) 25. BULKHEAD NUT
13. ADHESIVE TAPE (C709)(900 CONFIG)GLASS FABRIC 26. PERMASWEDGE UNION
TAPE (C710)(902 CONFIG) 27. NUT, COUPLING, ALUMINUM
Page 423
21-40-00 Original
Page 424
HEAT/DEFOG SYSTEM
INSPECTION/TEST
1. Heat/Defog System Inspection through to tube. Inspect for indication
of an air leak. If necessary, repair or
(Ref. Figure 601) replace.
A. Heat/Defog System Bleed Air (3). Inspect Sta. 230.03 tube insulation and
Engine/Firewall Inspection (Area 5) tape for tears and cuts that are through
(1). Open L260 and R260 (Ref. Section to tube. Inspect for indication1 of an air
06-00-00). leak. If necessary, repair or replace.
(2). Inspect engine bleed air check valve for (4). Inspect tubes for condition. If necessary,
condition and security. If necessary, repair or replace.
repair or replace.
(3). Inspect hose between right and left head baggage compartment interior
engine bleed air valve and firewall trim insulation panels (Ref. Section
fittings for condition. If necessary, 25-50-00).
repair or replace.
C. Under Floor Tube Assemblies Inspection
(4). Inspect bleed air firewall fittings for (Area 1 and 2)
cracks and indication of an air leak at
firewall gasket. If necessary, repair or (1). Remove AR165, AR138, and AR129
replace. (Ref. Section 06-00-00).
(5). Inspect bleed air flow control shutoff (2). Inspect tube inside/outside shields and
valve for security and condition. oxygen hose clamps for security. If
Electrical connector for corrosion. If necessary, repair or replace.
necessary, repair or replace. (3). Inspect tube insulation and tape for
(6). Inspect check valve to deck tube for tears and cuts that are through to tube.
condition, cracks, and indication of an Inspect for indication of an air leak. If
air leak. If necessary, repair or replace. necessary, repair or replace.
(7). Close L260 and R260 (Ref. Section (4). Install AR165, AR138, and AR129 (Ref.
06-00-00). Section 06-00-00).
B. Heat/Defog Tube Assemblies Inspection D. Control Cables Inspection (Area 1 and 2)

(Area 6)
(1). Inspect control cables for kinks crushed
(1). Remove right aft station 230.00 sleeve, and corrosion. Inspect for
bulkhead baggage compartment galling and indication of wear. If
interior trim insulation panels (Ref. necessary, repair or replace.
Section 25-50-00).
(2). Inspect control cable handles for
(2). Inspect roof to valve tube insulation security and loose or missing hardware.
and tape for tears and cuts that are If necessary, repair or replace.
Page 601
E. Aft Cabin Heat Ejector Inspection (Area 2) (3). Inspect ejector for security. If necessary,
repair or replace.
(1). Remove cabin compartment interior
trim insulation panel adjacent to (4). Inspect control cable for kinks, crushed
ejector outlet (Ref. Section 25-20-00). sleeve and corrosion. Inspect for galling
and indication of wear. If necessary,
(2). Inspect tube between flow control valve repair or replace.
and heat ejector insulation and tape for
tears and cuts that are through to tube. (5). Close N82, N106, and B142 (Ref.
If necessary, repair or replace. Section 06-00-00).
H. Heat/Defog Valve Inspection (Area 1)
(3). Inspect ejector bypass valve door for
easy movement. (1). Inspect valve housing for loose connec
tions at mating surfaces. If necessary,
(4). Inspect ejector for cracks. No damage repair or replace.
permitted.
(2). Inspect valve for security and indica
(5). Install cabin compartment interior trim tion of an air leak. If necessary, repair
insulation panel adjacent to ejector or replace.
outlet (Ref. Section 25-20-00).
(3). Check valve for full open and close
F. Flow Control Single Ball Valve Inspection positions and make sure it touches
(Area 2) stops. If necessary, adjust cable.
(1). Remove cabin compartment interior I. Rubber Ducts and Hoses Inspection
trim insulation panel adjacent to (Area 1)
ejector outlet (Ref. Section 25-20-00).
(1). Inspect rubber hoses and ducts for cuts,
(2). Inspect flow control valve housing for tears, and indication of deterioration. If
loose connections at mating surfaces. If necessary, repair or replace.
necessary, repair or replace. (2). Inspect for security of attach hardware.
If necessary, repair or replace.
(3). Inspect flow control valve for security,
condition, and indication of an air leak. J. Defog Manifold Inspection (Area 1)
If necessary, repair or replace.
(1). Inspect manifold for cracks and dela
(4). Operate check valve full open and close mination. If necessary, repair or
and make sure it touches stops. If replace.
necessary, adjust control cable.
(2). Inspect manifold attach hardware for
(5). Install cabin compartment interior security. If necessary, repair or replace.
panel adjacent to ejector outlet (Ref.
K. Foot Heater Valves Inspection (Area 1)
Section 25-20-00).
(1). Inspect valve and attach brackets for
G. Heat/Defog Ejector Inspection (Area 1) cracks. If necessary, repair or replace.
(1). Open N82, N106, and B142 (Ref. (2). Inspect control cable for easy operation.
Section 06-00-00). If necessary, repair or replace.
(2). Inspect ejector for cracks and separa (3). Inspect attach hardware for security. If
tion. No damage allowed. necessary, repair or replace.
Page 602
10
13
14
15 12 11
16
17 8
1 3
1
2
6
2
5
4
9G21026A
1. HEAT DEFOG MANIFOLD 10. MAIN BLEED AIR FIREWALL FITTING
2. FOOT HEATER VALVE 11. LH ENGINE BLEED AIR CHECK VALVE
3. FOOT HEATER CONTROL CABLE 12. ENGINE BLEED AIR TUBES
4. HEAT/DEFOG EJECTOR 13. RH ENGINE BLEED AIR CHECK VALVE
5. HEATER/DEFOG VALVE (FLOW CONTROL) 14. FLOW CONTROL SHUTOFF VALVE
6. HEATER/DEFOG CONTROL CABLE 15. ENGINE DECK FITTING
7. BLEED AIR TUBE 16. FLEXIBLE HEATER CONTROL CABLE
8. AFT CABIN HEAT EJECTOR 17. HEATING SYSTEM FLOW CONTROL VALVE SINGLE
9. UNION PERMASWEDGE FITTING (900 CONFIG) BALL
Figure 601. Heat/Defog System
Page 603
2
15 (7 PL)
8
Figure 602. Engine Bleed Air Check Valve / Flow Control Shutoff Valve
Page 604

1. ENGINE BLEED AIR FITTING 10. TUBE FLOW CONTROL SHUTOFF VALVE TO FITTING
2. ENGINE BLEED AIR CHECK VALVE 11. ELBOW
3. BOSS SEAL 12. BOLT
4. ENGINE TO VALVE HOSE (RH) 13. GASKETS
5. ENGINE TO VALVE HOSE (LH) 14. NUT, COUPLING, CRES
6. HEAT/DEFOG INBOARD FIREWALL TUBE 15. THREADLESS FLEXIBLE COUPLING
7. FIREWALL FITTING 16. TUBE, VALVE TO DECK
8. MAIN BLEED FITTING 17. NUT, COUPLING, ALUMINUM ALLOY
9. BLEED AIR FLOW CONTROL SHUTOFF VALVE
Page 605
2. Heat/Defog System Leak Check flow rate. Air flow rate must be less
Functional Test than 2.0 cfm (56.6 L/m).
(Ref. Figure 601, Figure 602, and Figure 603) (11). If the air flow rate is more than 2.0 cfm
(56.6 L/m), continue functional test as
follows:
(Ref. CSPSPM) (a). check all tube connections and
Item Nomenclature fittings above the engine deck for
C809 Leak Detector, Liquid leaks.
C220 Compound, AntiSeize (b). Apply liquid leak detector (C809) to
the flow control shutoff valve,
firewall fittings, main bleed air
Special Tools fitting, and tube and hose connectors.
(Ref. CSPSPM) (c). Make sure there are no air leaks
Item Nomenclature around the flow control shutoff valve,
Air Flow Measurement Test Set (Ref. firewall fittings, main bleed air
Figure 603) fitting, and tube and hose connectors.
(d). If necessary, repair air leaks.
(1). Open L260 and R260 (Ref. Section
06-00-00). (12). If air flow rate is less than 2.0 cfm
(56.6 L/m), continue functional test as
(2). Remove right aft station 230.00 follows:
(a). Set POWER switch on ELEC
interior trim insulation panels (Ref.
TRICAL MASTER panel to BAT/
Section 25-50-00).
EXT.
(3). Remove AR165, AR138, and AR129 (b). Set HEAT switch on utility panel to
(Ref. Section 06-00-00). OVRD.
(4). Disconnect hose (5) and install AN (c). Air flow rate must be less than 4.0
806J-12 plug in coupling nut (Ref. cfm (113.2 L/m).
Figure 602).
(13). If air flow rate is more than 4.0 cfm
(5). Disconnect hose (4) and install (113.2 L/m), continue functional test as
AN919-18J reducer in coupling nut follows:
(Ref. Figure 602).
(a). Check all tube connections and
(6). Set HEAT switch on utility panel to fittings for leaks.
OFF.
(b). Apply liquid leak detector (C809) to
(7). Make sure cabin flow control valve and tube connectors and fittings.
crew compartment heat/defog valve are
(c). Make sure there are no air leaks at
closed.
tube connections and fittings.
(8). Connect a test fixture as shown in (d). If necessary, repair air leaks.
Figure 603.
(14). If air flow is less than 4.0 cfm (113.2
(9). Apply regulated shop air 90-110 psig L/m), continue functional test as
(620.5-758.5 kPa) to air supply follows:
adapter.
(a). Manually operate flow control valve
(10). With a constant pressure of 90-110 to make sure aft cabin heat ejector
psig (620.5-758.5 kPa), check the air control cable is adjusted correctly.
Page 606
(b). Manually operate heat/defog valve to (19). Connect hose to check valve. Torque
make sure heat/defog control cable is coupling nut 500-600 in-lb (56.5-67.8
adjusted correctly. Check air flow to Nwm).
heat/defog manifold.
(20). Remove plug from left engine hose.
(c). Operate foot heater control cables, (21). Apply anti-seize compound (C220) to
check air flow to foot heaters. left engine check valve.
(15). Set HEAT switch on utility panel to (22). Connect hose to check valve. Torque
OFF. coupling nut 500-600 in-lb (56.5-67.8
Nwm).
(16). Set POWER switch on ELECTRICAL
MASTER panel to OFF. (23). Close L260 and R260 (Ref. Section
06-00-00).
(17). Remove reducer from right engine hose.
Compound, Anti-Seize (C220) head baggage compartment interior
trim insulation panels (Ref. Section
25-50-00).
(25). Install cabin floor access panels AR165,
outboard floor panel AR129 and cockpit
(18). Apply anti-seize compound (C220) to floor panel AR138 (Ref. Section
right engine check valve. 53-20-00).
Page 607
AIR SUPPLY
ADAPTER
PLUG AIR FLOW METER

RANGE: 0-4 CFM (0-115 L/m) MINIMUM
PRECISION: 5%
PRESSURE GAGE
RANGE: 0-150 PSIG (0-1034 kPa) MINIMUM
PRECISION: 5%
SHOP AIR SUPPLY PRESSURE

100-120 PSIG (689-827 kPa)
PRESSURE
GAUGE SHOP AIR
FEMALE QUICK CONNECT SUPPLY
AIR FLOW
CONTROL VALVE
AIR FLOW
METER
APPROXIMATELY 6 FT OF MALE QUICK CONNECT

FLEXIBLE AIR HOSE
9G21035C
Figure 603. Heat/Defog Leak Check Functional Test
Page 608
Section
215000
Air Conditioning
System
AIR CONDITIONING SYSTEM

1. Air Conditioning System Condenser Fans (EARLY CONFIG) -
The two fans provide ambient airflow across
The air conditioning system supplies ventila the condenser.
tion, temperature, and humidity control to the
cabin. Cooling Blowers (CURRENT CONFIG) -
The two blowers provide ambient airflow
Configuration - There are two configura across the condensers.
tions of the air conditioning system. They are Condenser - Changes high-pressure refriger
identified in this manual as the early configu ant gas into high-pressure refrigerant liquid.
ration (EARLY CONFIG) and current
configuration (CURRENT CONFIG). Those Receiver Dehydrator - Removes moisture
areas in which a configuration is not specified from the refrigerant liquid.
are the same for both configurations.
High Pressure Switch - De-energizes the
EARLY CONFIG - This configuration has compressor in a high pressure condition.
two condenser fans and one condenser. The Prevents damage to the air conditioning
fans and condenser are under the floor in the system.
baggage compartment.
Low Pressure Switch - De-energizes the
The receiver dehydrator is on the right side of compressor in a low pressure condition.
the transmission deck. This configuration is in Prevents damage to the air conditioning
use by aircraft with the PW206A/E engine. system.
Thermostatic Switch - Prevents the
CURRENT CONFIG - This configuration has evaporator from too much refrigeration or an
no condenser fans and two condensers. The icing condition.
condensers are attached to the oil coolers.
Thermal Expansion Valve - Controls the air
The receiver dehydrator is on the left side of conditioning system refrigerant that is put into
the transmission deck. This configuration is in the evaporator.
use by aircraft with the PW207E engine.
Evaporator - Supplies the cabin with fresh or
A. Components recirculated air.
Evaporator Fan - Pushes air through the
The air conditioning system contains the
evaporator.
components that follow:
Three Way Valve-Duct Assembly - Controls
Utility Control Panel - The five position the flow of recirculated or external air to the
rotary-switch AC/VENT controls the vent fan air conditioning system.
and air conditioning. The COOL HIGH
switch position supplies air conditioning at a Three Way Valve Control Cable - Controls
high volume. The COOL LOW switch position the position of the three way valve.
supplies air conditioning at a low volume.
B. Compressor Assembly
Compressor Assembly - Compresses the air The compressor is on the right engine accesso
conditioning refrigerant. The compressor ry gearbox.
changes the refrigerant from a low pressure
and temperature gas to a high pressure and The compressor is a shaft driven unit. The
temperature gas. internal drive shaft is controlled by a clutch.
The internal drive shaft will break away from
Lines and Tubing - Transfer the refrigerant the gearbox if the compressor seizes. This
through the air conditioning system. prevents damage to the engine.
Page 1
21-50-00 Revision 8
The AC/VENT rotary switch controls the

clutch. When the switch is set to COOL HIGH
or COOL LOW the clutch energizes and the G. Receiver Dehydrator
compressor drive shaft turns. EARLY CONFIG - The receiver dehydrator
A low pressure switch monitors the evaporator is on the right side of the transmission deck. It
output pressure to the compressor. The low is on the high pressure line after the condens
pressure switch de-energizes the compressor er.
if a low pressure condition occurs. The high CURRENT CONFIG - The receiver dehydra
pressure switch monitors the condenser tor is on the left side of the transmission deck.
output pressure. The high pressure switch It is on the high pressure line after the
de-energizes the compressor if a high pressure condensers.
condition occurs.
The dehydrator removes moisture from the
C. Lines and Tubing liquid refrigerant that exits the condenser. The
dehydrator is also the reservoir for the air
Lines and tubing transfer refrigerant gas and conditioning system. Liquid refrigerant goes
liquids through the air conditioning system. into the receiver dehydrator to be filtered. The
liquid refrigerant goes through a desiccant to
D. Condenser Fans (EARLY CONFIG) -
observe moisture.
The two condenser fans are on top of the H. Sight Glass
condenser. The fans are attached side-by-side.
They move ambient air across the condenser. EARLY CONFIG - The sight glass and
The condenser fans are energized by the fan servicing points on the inboard side of the
relays. This is done by when the COOL compressor.
HIGH or COOL LOW selection is made on
the utility panel. The CURRENT CONFIG has an additional
sight glass on the evaporator outlet tube.The
E. Cooling Blowers (CURRENT CONFIG)- servicing points are on the tubes next to the
sight glass.
Two cooling blowers attach to the main
transmission housing. The blowers provide The sight glass shows the amount of charge in
ambient air to cool the main transmission oil the system. The charge is low if bubbles show
coolers and air conditioning condensers. in the glass.
F. Condenser A filter is on the pickup tube to stop particles

that can possibly go into the thermal expan
EARLY CONFIG - There is one condenser sion valve.
under the baggage compartment floor panel
(Ref. Figure 1). I. High Pressure Switch
The high pressure switch is near the receiver
CURRENT CONFIG - There are two
dehydrator.
condensers. Each condenser is attached to a
main transmission oil cooler (Ref. Figure 2). The switch monitors the pressure of the
refrigerant that exits the condenser. The high
A condenser is made of aluminum core tubes pressure switch de-energizes the compressor
and aluminum fins in an aluminum housing. assembly when the refrigerant pressure is
A condenser is a heat exchanger. Hot and high more than 300 psi.
pressure refrigerant gas from the compressor J. Low Pressure Switch
moves through the core tubes of the condenser.
The air flows around the core tubes to remove The low pressure switch senses the
heat from the refrigerant gas. Condensation pressure of the refrigerant that exits the
occurs as the gas cools . The high pressure gas evaporator assembly. The low pressure switch
becomes a liquid. The high pressure refriger de-energizes the compressor assembly when
ant liquid then goes to the evaporator. the pressure is less than 15 psi.
Page 2
Revision 8 21-50-00
K. Thermostatic Switch N. Evaporator Fan

The thermostatic switch is in the evaporator The evaporator fan is on the right side of the
cooling duct. evaporator.
The thermostatic switch controls the compres A two speed 28 Vdc electric motor energizes
sor. The thermostatic switch prevents an icing the evaporator fan. The fan starts the airflow
condition or too much refrigeration. that moves the cabin air or fresh air through
L. Thermostatic Expansion Valve the evaporator. The air cools as it flows over
the evaporator. The routing of the ducts sends
The thermostatic expansion valve (TXV) is in the air to the cabin gasper assemblies.
the evaporator.
O. ThreeWay Valve Duct Assembly
The valve controls the high pressure liquid
refrigerant flow that goes into the evaporator The three-way valve duct assembly is next to
as a gas. the water separator.
The valve is a spray nozzle. It is in operation The duct assembly lets the air move through
at the same time as the compressor. The valve the air conditioning ducts to cool the crew and
adjusts for temperature to control the liquid passenger compartment.
refrigerant flow into the evaporator.
P. Three Way Valve
M. Evaporator Assembly
The three way valve is next to the evaporator
The evaporator assembly is in a housing that fan.
attaches to the air plenum duct.
The three way valve is a butterfly disc valve.
The evaporator supplies a heat exchange for The three way valve lets cabin recirculated air,
the cabin air to cool. The internal chamber of outside fresh air, or both into the air condition
the evaporator lets the low pressure liquid ing system.
refrigerant expand into a low temperature gas.
Q. ThreeWay Valve Control Cable
When the AC/VENT rotary switch is set to
COOL HIGH or COOL LOW the evaporator The three-way valve control cable is above the
fan energizes. The fan then recirculates the right pilot seat.
cabin air or fresh air through the evaporator.
The three-way valve opens to let warm cabin The three-way valve control cable is a push
air or fresh air go into the fresh air vent pull cable. The three-way valve control cable
system ducts. The low pressure gas in the operates the three way valve. The pilot can set
evaporator cools the air that flows over the the cable position for outside fresh air, cabin
evaporator. recirculated air, or both.
Page 3
21-50-00 Revision 8
RECEIVER COMPRESSOR
WATER SEPARATOR DEHYDRATOR
3-WAY VALVE UNIVERSAL

DUCT ASSEMBLY BULKHEAD FITTING
HIGH PRESSURE
GAUGE SWITCH
3-WAY VALVE
3-WAY VALVE
CONTROL CABLE AIR PLENUM LOW PRESSURE
DUCT GAUGE SWITCH
EVAPORATOR
FAN
THERMOSTATIC
SWITCH
EVAPORATOR
LINES AND
TUBING
CONDENSER SCOOP
EMI FILTERS CONDENSER

CONDENSER FANS
9G21015B
Figure 1. Air Conditioning System EARLY CONFIG
Page 4
Revision 8 21-50-00
COMPRESSOR
RH CONDENSER
WATER SEPERATOR
HIGH PRESSURE
GUAGE SWITCH
3-WAY VALVE LOW PRESSURE SWITCH
DUCT ASSEMBLY
RECIEVER
3-WAY VALVE DEHYDRATOR
3-WAY VALVE
CONTROL CABLE THERMOSTATIC
SWITCH AIR PLENUM
DUCT
EVAPORATOR
FAN
EVAPORATOR LINES AND
TUBING
SERVICING SIGHTGLASS
PORTS
9G21_040
Figure 2. Air Conditioning System CURRENT CONFIG
Page 5
21-50-00 Revision 8
CABIN/PASSENGER COMPARTMENT
AIR OUTLET
6 PLACES
HIGH PRESSURE
SWITCH
RECEIVER/
DRYER
THERMAL
EXPANSION

VALVE EVAPORATOR
3 - WAY
VALVE
WATER RAM AIR IN
SEPARATOR

FAN
THERMOSTATIC
CONDENSER

SWITCH OVERBOARD DRAIN
OVERBOARD
OVERBOARD

DRAIN
CONDENSER

FANS

COMPRESSOR ASSEMBLY

LOW PRESSURE
SWITCH

CREW/PILOT COMPARTMENT
HIGH PRESSURE LIQUID

RECIRCULATING
AIR INLET LOW PRESSURE LIQUID

AIR OUTLET FROM CABIN
HIGH PRESSURE GAS

4 PLACES
LOW PRESSURE GAS
9G21-020A
Figure 3. Air Conditioning System Diagram (EARLY CONFIG)
Page 6
Revision 8 21-50-00
CABIN/PASSENGER COMPARTMENT
AIR OUTLET
6 PLACES
HIGH PRESSURE
SWITCH
THERMAL RECEIVER/
EXPANSION DRYER
VALVE
EVAPORATOR
3 - WAY
VALVE
WATER RAM
SEPARATOR AIR IN

FAN
CONDENSER
THERMOSTATIC OVERBOARD DRAIN

SWITCH
OVERBOARD

OVERBOARD
DRAIN

LH COOLING
BLOWER
RH COOLING CONDENSER

BLOWER

OVERBOARD

COMPRESSOR
ASSEMBLY

LOW PRESSURE SWITCH
CREW/PILOT COMPARTMENT

HIGH PRESSURE LIQUID
RECIRCULATING

AIR INLET LOW PRESSURE LIQUID
FROM CABIN

AIR OUTLET HIGH PRESSURE GAS
4 PLACES
LOW PRESSURE GAS
9G21-039
Figure 4. Air Conditioning System Diagram (CURRENT CONFIG)
Page 7/(8 blank)

21-50-00 Revision 8
AIRCONDITIONING SYSTEM
FAULT ISOLATION
1. AirConditioning System Troubleshooting Troubleshooting tables are used with system
schematics, electrical wiring diagrams,
(Ref. Figure 101 thru Figure 103) serviceable checks, and also refer to other
procedures in this manual.
The troubleshooting procedures in Table 101 Wiring diagrams are available in the Rotor
are air-conditioning system faults which craft Maintenance Manual CSP-900RMM-3
possibly can occur. (ref. Section 98-40-00).
Table 101. AirConditioning System Troubleshooting
Air Condition does not Circuit breaker COMP Replace or reset COMP circuit 960000
operate when the COOL (CB17) open. breaker (CB17) as necessary.
LOW or COOL HI selection
is made on the Utility Control Defective air condition Replace the relay. 960000
disable relay K75.
Panel during normal engine
operation. Open wire between relay Do a test on the wires for a 206000
(See Note 1) K75X2 and P104ZF serviceable condition. Make
(on the IIDS). repairs as necessary.
Defective compressor Replace the compressor. 215000
solenoid.
Defective time delay relay Replace the time delay relay. 960000
K73/4.
System pressure is low. Service the air conditioning 120000
system.
A leak in the air conditioning 120000
system. Repair as necessary.
Defective low pressure Replace the low pressure 215000
switch. switch.
System pressure is high. Defective thermostatic 215000
expansion valve (TXV).
Replace the valve.
Condenser is dirty, clean as 215000
necessary. Remove blockage
from the air inlet as necessary.
EARLY CONFIG 215000
Condenser fans do not operate.
Repair or replace as necessary.
Defective IIDS. Replace the IIDS. 953000
Page 101
Table 101. AirConditioning System Troubleshooting (Cont.)

Evaporator fan does not Circuit Breaker VENT EVAP Replace or reset the VENT 206000
operate. (CB18) is open. EVAP circuit breaker (CB18) as
necessary.
Open ground wire from Do a test on the wires for a 206000
AC/Vent Fan switch to serviceable condition. Make
GS 104D ground stud. repairs as necessary.
Defective K100 power relay. Replace the K100 power relay. 960000
Defective evaporator fan Replace the evaporator fan. 215000
motor.
Defective wiring. Do a test on the wires for a 206000
serviceable condition. Make
repairs as necessary.
EARLY CONFIG Defective relay K83/4 Replace the relay. 960000

Condenser fan does not condenser fan #1.
operate.
Defective relay K81/2 Replace the relay. 960000
condenser fan #2.
Circuit breaker CNDSR FAN Replace or reset circuit breaker 960000
1 (CB56) is open. CNDSR FAN 1 (CB56) as
necessary.
Circuit breaker CNDSR FAN Replace or reset circuit breaker 960000
2 (CB26) is open. CNDSR FAN 2 (CB26) as
necessary.
Defective rotor select A/C Replace the switch. 960000
VENT fan switch S3.
Defective wiring. Do a test on the wires for a 206000
serviceable condition. Make
repairs as necessary.
Suction line or low pressure Defective thermostatic Replace the Thermostatic 215000
line has ice on the other side expansion valve (TXV). Expansion Valve (TXV).
of the thermal bulb position.
Evaporator has frost on it. Flooded evaporator. Replace the Thermostatic 215000
Incorrect adjustment on Expansion Valve (TXV)
expansion valve (TXV).
Evaporator has ice on it. Defective thermostatic Replace thermostatic switch. 215000
switch.
NOTES:
(1) The IIDS automatically deenergizes the airconditioning system if there is an engine failure while
inflight. The message AC DISABLE will show on the alpha/numeric display. The electrical ground to the
air condition disable relay (K75) will be removed through the IIDS. It is necessary for the two engines to
be fully operational while inflight for the airconditioning system to operate.
(2) The Aircraft On Ground relay (AOG) lets a single (right) engine operate the airconditioning service and
other maintenance (ref. Section 953000).
Page 102
1
7
6
3 4
9
5
10
13
14
12
11
17
17
16 8
15
2
9G21029B
1. 3WAY VALVE CONTROL CABLE 10. AIR PLENUM
2. 3WAY VALVE 11. LINES AND TUBING
3. 3WAY VALVE DUCT ASSEMBLY 12. EVAPORATOR
4. WATER SEPARATOR 13. EVAPORATOR FAN
5. HIGH PRESSURE GAUGE SWITCH 14. THERMOSTATIC SWITCH
6. RECEIVER DEHYDRATOR 15. CONDENSER
7. COMPRESSOR 16. CONSENDER FAN
8. UNIVERSAL BULKHEAD FITTING 17. EMI FILTERS
9. LOW PRESSURE GAUGE SWITCH
Figure 101. AirConditioning System (Vapor Cycle Cooling System) EARLY CONFIG
Page 103
14 7
4
5
8
3
12
11
13 10
15
9G21_041
1. 3WAY VALVE CONTROL CABLE 9. AIR PLENUM
2. 3WAY VALVE 10. LINES AND TUBING
3. 3WAY VALVE DUCT ASSEMBLY 11. EVAPORATOR
4. WATER SEPARATOR 12. EVAPORATOR FAN
5. HIGH PRESSURE GAUGE SWITCH 13. THERMOSTATIC SWITCH
6. RECEIVER DEHYDRATOR 14. CONDENSER
7. COMPRESSOR 15. SIGHT GLASS
8. LOW PRESSURE GAUGE SWITCH
Figure 102. AirConditioning System (Vapor Cycle Cooling System) CURRENT CONFIG
Page 104
A620
ELECTRICAL LOAD CENTER
K7-5
AIR COND CB17 CB19
DISABLE RELAY COMP EVAP
A2 J8 P381
A3 28VDC
IIDS W123 A2 28VDC A
A1 5A 20A
J4 P104 X1
A606 CB18
UTILITY CONTROL PANEL P377 J3 X2 VENT/EVAP
AIR COND ZF
S3 V 28VDC
DISABLE C
AC/VENT 20A
SWITCH J3 P377
P117 W124 P374 J2
COOL HI J1 S
1 W
2 COOL LO A 22
CA1
3 OFF
4 VENT LO R
K7-3/4
TIME DELAY 2.0 SEC RELAY
A3
A2 A1
1 COOL HI T
X1
2 COOL LO
X2
CA2 3 OFF
TB1-3
4 VENT LO
A E J N T U
5
VENT HI J5 P379
C L
COOL HI K8-3/4
CB56 CONDENSER FAN 1 RELAY
D CNDSR FAN 1
1
B3 B2
2 COOL LO 28VDC
15A B1
CA3 A3
3 OFF A2
X1 EARLY
4 VENT LO A1 CONFIG
5 VENT HI TB1-3
X2
B F K P W
21
M
K8-1/2
CB26 CONDENSER FAN 2 RELAY
GS104-D CNDSR FAN 2 B3
E E B2
28VDC
15A B1
A3
E H E A2
A1
GS106-J X1
X2
A612
FWD INTERCONNECT PANEL
P172 J1 J1 P171
43 10 A
9G210241B
Figure 103. AirConditioning System Wiring Diagram (Sheet 1 of 2)
Page 105
A404
EVAPORATOR FAN
W123 K100 W305
P381 POWER RELAY P516 J1
B2 B1
A B 28V DC
A2 A1
C A 28V DC
P377 SPEED CONTROL

X1 F
S
A X2 D PWR GND
J155 P155 E PWR GND
W F GS400 E
COMPRESSOR
R C SOLENOID
W305-SP1 S302
THERMOSTATIC
T D
PS2 PS1 SWITCH
HIGH PRESSURE LOW PRESSURE
SWITCH SWITCH A
P502 P503
C C
U E B B
B
A A
W125
P379 TB301
L A B
A411
W304
A680 CONDENSER FAN
FAN EMI FILTER #1
P501 J1
SP1 RED (+) SP4 A 28V DC

SP2 BLACK (-) SP5 B PWR GND
EARLY CONFIG
SP3 GREEN (GND) SP6 D CHASSIS GND
E E
GS300
A412
A681 CONDENSER FAN
TB301 W304 FAN EMI FILTER #2
M C D P500 J1
SP7 RED (+) SP10 A 28V DC
SP8 BLACK (-) SP11 B PWR GND
SP9 GREEN (GND) SP12 D CHASSIS GND
E
E
GS300
9G210242C
Figure 103. AirConditioning System Wiring Diagram (Sheet 2 of 2)
Page 106
9G21-034
Figure 104. Utility Control Panel (AirConditioning System)
Page 107
Page 108
AIRCONDITIONING SYSTEM
REMOVAL / INSTALLATION
1. Compressor Assembly (4). Install the engine accessory drive cover
and gasket.
A. Compressor Assembly Removal
(a). Torque the nuts.
(Ref. Figure 401)
C. Compress Assembly Installation
The receiver dehydrator must
CAUTION be replaced each time the com (Ref. Figure 401)
pressor is removed, or the air-conditioning
(AC) system is opened. An early failure of Consumable Materials
the compressor can occur. (Ref. CSPSPM)
(1). Open Access Panel R210 (ref. Section Item Nomenclature
06-00-00). C106 Oil, Lubricating
(2). Evacuate AC system (ref. Section

12-00-00). (1). If the rotorcraft was operated without
the compressor installed, do these
(3). Disconnect Electrical Connector SP1 steps:
(5).
(a). Remove engine accessory drive cover
(4). Disconnect outlet hose (2). and gasket.
(5). Disconnect inlet hose (3). (b). Remove pressure caps from flared
tube union and flared tube tee and
(6). Disconnect drain hose (4). install drain hose (4).
(7). Remove nuts (6) and washers (7). 1). Torque both captive nuts of drain
(8). Carefully remove compressor (1). hose (4) 50 to 65 in-lb (5.65 to
7.34 Nm).
(a). Remove and discard packings (8, 9).
(c). Remove pressure cap from swivel nut
B. Operation Without the Compressor tee and install inlet hose (3).
Assembly Installed
1). Torque the nut of inlet hose (3) 460
NOTE: If the rotorcraft is to be operated with to 550 in-lb (51.97 to 62.14 Nm).
out the compressor installed, do these steps.
(d). Remove pressure cap from fitting or
(1). Remove outlet hose (2) and install a swivel nut tee and install outlet hose
pressure cap on the fitting or swivel nut (2).
tee.
1). Torque the nut of outlet hose (2)
(a). Torque the cap. 230 to 260 in-lb (25.99 to 29.38
Nm).
(2). Remove inlet hose (3) and install a
pressure cap on the swivel nut tee. (2). If the compressor (1) is replaced, or the
AC system was opened, do these steps:
(a). Torque the cap.
(a). Do the Evaporator Internal Cleaning
(3). Remove AC compressor drive pad drain procedure (ref. CSP-SPM, Section
hose (4) and install pressure caps on 20-20-00).
the flared tube union and flared tube
tee. (b). Do the Condenser Internal Cleaning
procedure for both condensers (ref.
(a). Torque the caps. CSP-SPM, Section 20-20-00).
Page 401
(c). Do the Hose and Tube Internal (a). Torque the fitting of inlet hose (3)
Cleaning procedure (ref. CSP-SPM, 460 to 500 in-lb (51.97 to 56.49
Section 20-20-00). Nm).
Oil, Lubricating (C106) (8). Connect outlet hose (2).
(a). Torque the fitting of outlet hose (2)

230 to 260 in-lb (25.99 to 29.38
Nm).
(3). Lubricate packings (8, 9) with lubricat (9). Connect Electrical Connector SP1 (5).
ing oil (C106).
(4). Install packings (8, 9) on compressor CAUTION be replaced each time the com
(1). pressor is removed, or the AC system is
opened. An early failure of the compressor
(5). Install compressor (1) with nuts (6) and can occur.
washers (7).
(10). Remove and replace the receiver
(a). Torque nuts (6) 100 to 140 in-lb dehydrator (ref. Procedure 22.).
(11.30 to 15.82 Nm).
(11). Service compressor reduction gearbox
(6). Connect drain hose (4). (ref. Section 12-00-00).
(a). Torque both captive nuts of drain (12). Service AC system (ref. Section
hose (4) 50 to 65 in-lb (5.65 to 7.34 12-00-00).
Nm).
(7). Connect inlet hose (3). 06-00-00).
6 7
2
8
9
1
5 4
9G21008B
1. AC COMPRESSOR (REF. IPL, 215000, FIG. 3) 6. NUT
2. OUTLET HOSE (HIGHPRESSURE) 7. WASHER
3. INLET HOSE (LOWPRESSURE) 8. PACKING
4. DRAIN HOSE (COMPRESSOR DRAIN) 9. PACKING
5. ELECTRICAL CONNECTOR SP1
Figure 401. Removal and Installation of the Compressor (Right Engine)
Page 402
Page 403
16
14
12
14 12
1
1 (REF)
7 15
8
2 (REF)
2
3
4
5
6
10 9 10
11
DECK (REF)
6 5 155.50 BULKHEAD (REF) 9G21030B
1. 3WAY VALVE DUCT 9. WASHER
2. 3WAY VALVE CABLE 10. JAM NUT
3. SPLIT GROMMET 11. CABLE BRACKET
4. CABLE HANDLE BRACKET 12. VBAND CLAMP
5. WASHER 13. EVAPORATOR FAN
6. SCREW 14. BAND CLAMP
7. WASHER 15. BULKHEADTOVALVE DUCT
8. COTTER PIN 16. SEPARATORTO VALVE DUCT
Figure 402. Removal and Installation of ThreeWay Valve Cable and Duct
Page 404
2. ThreeWay Valve Cable (7). Connect cable (2) washers (7), and new
cotter pin (8).
A. ThreeWay Valve Cable Removal
(8). Adjust linkage of cable (2) to get full
(Ref. Figure 402) travel of duct (1).
(1). Open Access Panel R155 (ref. Section (9). Torque jam nuts (10) 270 to 300 in-lb
06-00-00). (30.50 to 33.90 Nm).
(2). Remove cotter pin (8), washers (7), and Sealing Compound (C205)
end of cable (2) from duct (1).
(3). Remove aft jam nut (10) and washer

(9).
(10). Environmentally seal split grommet (3)
(4). Pull cable (2) through cable bracket and cable (2) with sealing compound
(11). (C205) (ref. CSP-SPM, Section
20-50-00).
(5). Remove forward jam nut (10) and
washer (9). (11). Close Access Panel R155 (ref. Section
06-00-00).
(6). Remove screws (6) and washers (5).
(7). Carefully remove sealant from split 3. ThreeWay Valve Duct Assembly
grommet (3).
A. ThreeWay Valve Duct Assembly
(8). Move cable (2) aft from bracket (4) to Removal
remove.
(Ref. Figure 402)
B. ThreeWay Valve Cable Installation
(Ref. Figure 402) 06-00-00).
(2). Remove cotter pin (8), washers (7), and

Consumable Materials the end of cable (2) from duct (1).
(Ref. CSPSPM)
Item Nomenclature (3). Remove V-band clamp (12).
C205 Sealing Compound (4). Loosen band clamps (14).
(5). Remove duct (1).

(1). Put cable (2) through split grommet (3).
B. ThreeWay Valve Duct Assembly
(2). Put three-way valve cable (2) into cable Installation
handle bracket (4).
(Ref. Figure 402)
(3). Install washers (5) and screws (6).
(1). Install duct (1) on evaporator fan (13)
(a). Torque screws 20 to 25 in-lb (2.26 with V-band clamp (12).
to 2.82 Nm).
(2). Install flexible ducts (15, 16) on duct (1)
(4). Install washer (9) and forward jam nut with band clamps (14).
(10).
(3). Install cable (2), washers (7), and new
(5). Put cable (2) through cable bracket cotter pin (8) on duct (1).
(11).
(6). Install washer (9) and aft jam nut (10). 06-00-00).
Page 405
10
5
3
5 8
4 3
5
3
3
3
1
VIEW ROTATED
2
9G21021C
1. EVAPORATOR FAN (REF. IPL, 215000, FIG. 1 AND 6. SCREW
FIG. 2) 7. FLEXIBLE DUCT
2. WASHER 8. ELECTRICAL CONNECTOR P516
3. WASHER 9. VBAND CLAMP
4. SCREW 10. 3WAY VALVE DUCT
5. SCREW
Figure 403. Removal and Installation of the Evaporator Fan
Page 406
4. Evaporator Fan (1). Prepare mating surfaces of evaporator

fan (1) and the upper deck for an
A. Evaporator Fan Removal electrical bond (ref. CSP-SPM, Section
(Ref. Figure 403) 20-50-00).
(1). Remove Access Panel T155 (ref. Section (2). Install washers (2) between the upper
53-30-00). deck and evaporator fan (1).
(2). Remove V-band clamp (9) and duct NOTE: Only install washers (2) with the -101
(10). evaporator fan.
(3). Disconnect Electrical Connector P516 (3). Install evaporator fan (1) with washers
(8). (3) and screws (4, 5).
(4). Carefully remove sealant from the (a). Torque screws (4, 5) 20 to 25 in-lb
bottom of evaporator fan (1) and upper (2.26 to 2.82 Nm).
deck.
(5). Remove screws (6) and washers (3) to
disconnect flexible duct (7) from
evaporator fan (1).
(6). Remove screws (4, 5) and washers (3).
(4). Environmentally seal screws (4, 5),
(7). Remove evaporator fan (1). washers (3), and mating surfaces with
(8). Remove washers (2). sealing compound (C205) (ref. CSP-
SPM, Section 20-50-00).
NOTE: Washers (2) are only installed with the
-101 evaporator fan. (5). Attach flexible duct (7) to evaporator
fan (1) with screws (6) and washers (3).
B. Evaporator Fan Installation
(a). Torque screws (6) 20 to 25 in-lb
(Ref. Figure 403) (2.26 to 2.82 Nm).
Consumable Materials (6). Connect Electrical Connector P516 (8).

(Ref. CSPSPM)
(7). Install V-band clamp (9) and duct (10).
Item Nomenclature
C205 Sealing Compound (8). Install Access Panel T155 (ref. Section
53-30-00).
Page 407
21 (REF)
21
25
26
22 8 (REF)
1 2 3 9 (REF)
4
1 (REF)
5
23 (10 PL)
24 (10 PL)
VIEW ROTATED
6
16 7
20 (NOTE 1) 15
17 (6 PL) 12
18 (6 PL) 13 (10 PL) 11
19 (6 PL) 14 (10 PL) 8 (3 PL)
(NOTE 2) 10 9 (3 PL)
1 (REF)
NOTE 3
4.20-4.80 INCH
41 (2 PL) (103.7-121.9 MM)

40 (2 PL)
15 (REF)

27 29 42
22 (REF)

4 (REF) 28 VIEW ROTATED
LOOKING UP 40 (2 PL)

30
31 39 (2 PL)

33
5 (REF)
6 (REF)
34
38 32
37
35
12 (REF) 36
NOTES:
1. GASPER PLENUM SHOWN FOR ROTORCRAFT SERIAL NUMBER 900-00039 AND SUBSEQUENT OR
EARLIER SERIAL NUMBERS THAT HAVE COMPLETED SL900-035.
2. NUTS ARE INSTALLED ON ROTORCRAFT SERIAL NUMBER 900-00010 AND 900-00011 ONLY.
3. INSTALL TEMPERATURE PROBE APPROXIMATELY AS SHOWN. PROBE MUST BE 0.0 TO 0.2 INCH (0 TO 5 MM)
BELOW THE MATING SURFACE OF THE EVAPORATOR. 9G21051
Figure 404. Removal and Installation of the Evaporator (EARLY CONFIG)
Page 408

1. OUTLET SHROUD (REF. IPL, 215000, FIG. 1) 22. THERMOSTATIC SWITCH
2. BAND CLAMP 23. SCREW
3. DUCT 24. WASHER
4. EXPANSION VALVE 25. BAND CLAMP
5. ADAPTER 26. INLET SHROUD
6. TUBE 27. EVAPORATOR INLET PORT
7. TUBE 28. WASHER
8. SCREW 29. SCREW
10. BRACKET 31. STRAINER
11. GASKET 32. CLAMP
12. UNION 33. SENSE TUBE
13. SCREW 34. BAND CLAMP
14. WASHER 35. SENSE ELEMENT
15. EVAPORATOR 36. RUBBER (C610)
16. GASKET 37. GLASS FABRIC TAPE (C710)
17. SCREW 38. NUT
18. WASHER 39. SCREW
19. NUT 40. WASHER
20. GASPER PLENUM 41. NUT
21. DUCT 42. GROMMET
5. Evaporator Outlet Shroud (EARLY (a). Torque screws (23) 20 to 25 in-lb

CONFIG) (2.26 to 2.82 Nm).
A. Outlet Shroud Removal (2). Connect duct (3) to outlet shroud (1).
(Ref. Figure 404) (3). Install band clamp (2).
(1). Remove Access Panel T155 (ref. Section (4). Install washers (18), screws (17), and
53-30-00). nuts (19) (if installed).
NOTE: If the rotorcraft uses nuts (19), install
(2). Remove band clamp (2).
screws (17) with heads on aft side of outlet
(3). Disconnect duct (3) from outlet shroud shroud (1).
(1). (a). Torque nuts (19) or screws (17) 20 to
(4). Remove nuts (19) (if installed), washers 25 in-lb (2.26 to 2.82 Nm).
(18), and screws (17). Sealing Compound (C205)
(6). Remove outlet shroud (1) and gasket
(11).
(5). Apply sealing compound (C205) to
B. Outlet Shroud Installation mating surfaces, washers (24), and
screws (23).
(Ref. Figure 404)
(6). Install Access Panel T155 (ref. Section
53-30-00).
(Ref. CSPSPM) 6. Evaporator Assembly (EARLY CONFIG)
Item Nomenclature
A. Evaporator Removal
(Ref. Figure 404)
(1). Install gasket (11), outlet shroud (1), (1). Evacuate AC system (ref. Section
washers (24), and screws (23). 12-00-00).
Page 409
(2). Remove outlet shroud (1) (ref. Proce (a). Torque adapter (5) 230 to 260 in-lb
dure 5.A.). (25.99 to 29.38 Nm).
(3). Remove glass fabric tape (C710) (37) (7). Connect tube (6) to adapter (5).
and rubber (C610) (36) from sense
(a). Torque the captive nut of tube (6) 230
element (35) and forward end of tube
to 260 in-lb (25.99 to 29.38 Nm).
(7).
(8). Put sense element (35) against tube (7)
(4). Loosen band clamp (34) and remove
at the 3 or 9 o'clock position, no more
sense element (35) from tube (7).
than 12 inch (305 mm) along tube (7)
(5). Disconnect tube (7). from its connection to evaporator (15).
(6). Remove union (12). NOTE: Do not put rubber between sense ele
ment (35) and tube (7).
(7). Disconnect tube (6).
(9). Put rubber (C610) around sense
(8). Remove adapter (5). element (35) and full length of tube (7).
(9). Remove screws (13) and washers (14). (10). Wind glass fabric tape (C710) on rubber
(C610).
(10). Remove evaporator (15) and gasket
(11). (11). Install outlet shroud (1).
B. Evaporator Installation The receiver dehydrator must

CAUTION be replaced each time the com
(Ref. Figure 404) pressor is removed, or the AC system is
can occur.
(Ref. CSPSPM) (12). Remove and replace the receiver
Item Nomenclature dehydrator (ref. Procedure 22.).
C610 Rubber, Expanded
(13). Service AC system (ref. Section
C710 Tape, Glass Fabric 12-00-00).
7. Expansion Valve (EARLY CONFIG)
(1). Put gasket (11) and evaporator (15) in
their installed position. A. Expansion Valve Removal
(2). Install screws (13) and washers (14). (Ref. Figure 404)
(a). Torque screws (13). (1). Remove evaporator (15) (ref. Procedure
6.A.).
(3). Install outlet shroud (1) (ref. Procedure
5.B.). (2). Disconnect evaporator inlet port (27).
(4). Install union (12) in the outlet of (3). Disconnect sense tube (33).
evaporator (15). (4). Remove nut (38), screw (29), and
(a). Torque union (12) 460 to 500 in-lb washer (28).
(51.97 to 56.49 Nm). (5). Remove expansion valve (4) and clamp
(5). Connect tube (7) to union (12). (32).
B. Expansion Valve Installation
(a). Torque captive nut of tube (7) 460 to
500 in-lb (51.97 to 56.49 Nm). (Ref. Figure 404)
NOTE: Make sure washer (30) and strainer (1). Put expansion valve (4) and clamp (32)
(31) are installed in expansion valve. in position.
(6). Install adapter (5). (2). Connect evaporator inlet port (27).
Page 410
(3). Connect sense tube (33). B. Inlet Shroud Installation

(4). Install washer (28), screw (29), and nut (Ref. Figure 404)
(38).
(1). Put inlet shroud (26) in position.
(a). Torque nut (38) 18 to 22 in-lb (2.03
to 2.49 Nm). (2). Connect duct (21) to inlet shroud (26).
(5). Torque the captive nut of sense tube (3). Install band clamp (25).
(33) 60 to 80 in-lb (6.78 to 9.04 Nm).
(4). Install evaporator (15) (ref. Procedure
(6). Torque the captive nut of evaporator 6.B.).
inlet port (27) 150 to 250 in-lb (16.95
to 28.25 Nm). 10. Thermostatic Switch (EARLY CONFIG.)
(7). Install evaporator (15) (ref. Procedure A. Thermostatic Switch Removal
6.B.).
(Ref. Figure 404)
8. Expansion Valve Strainer (EARLY
CONFIG) (1). Remove outlet shroud (1) (ref. Proce
dure 5.A.).
A. Strainer Removal
(2). Remove nuts (41), screws (39), and
(Ref. Figure 404) washers (40).
(1). Disconnect tube (6) from adapter (5). (3). Carefully straighten the temperature
probe as you pull it through grommet
(2). Remove adapter (5). (42).
(3). Remove strainer (31) and washer (30). (4). Remove thermostatic switch (22).
B. Strainer Installation
B. Thermostatic Switch Installation
(Ref. Figure 404)
(Ref. Figure 404)
(1). Install washer (30) and strainer (31).
(1). Install thermostatic switch (22) with
(2). Install adapter (5). screws (39), washers (40), and nuts
(41).
(a). Torque adapter (5) 230 to 260 in-lb
(25.99 to 29.38 Nm). (a). Torque nuts (41) 20 to 25 in-lb (2.26
to 2.82 Nm).
(3). Connect tube (6).
(2). Carefully bend the temperature probe
(a). Torque the captive nut of tube (6) 230 as shown (ref. Figure 404, Detail C).
to 260 in-lb (25.99 to 29.38 Nm).
(3). Install outlet shroud (1) (ref. Procedure
9. Evaporator Inlet Shroud (EARLY CONFIG) 5.B.).
A. Inlet Shroud Removal
11. Evaporator Aft Mounting Bracket (EARLY
(Ref. Figure 404) CONFIG)
(1). Remove evaporator (15) (ref. Procedure A. Bracket Removal

6.A.).
(Ref. Figure 404)
(2). Remove band clamp (25).
(1). Remove inlet shroud (26) (ref. Proce
(3). Disconnect duct (21) from inlet shroud dure 9.A.).
(26).
(2). Remove screws (8), washers (9), and
(4). Remove inlet shroud (26). bracket (10).
Page 411
B. Bracket Installation (1). Install bracket (10) with washers (9)

and screws (8).
(Ref. Figure 404) (a). Torque screws (8) 20 to 25 in-lb
(2.26 to 2.82 Nm).
Consumable Materials (2). Apply sealing compound (C205) to
(Ref. CSPSPM) mating surfaces, washers (9), and
Item Nomenclature screws (8).
C205 Sealing Compound (3). Install inlet shroud (26) (ref. Procedure
9.B.).
Page 412
1 (REF)
38 (2 PL)
39 (4 PL)
NOTE 3 40 (2 PL)
19
41
0.22-0.28 INCH
(5.6-7.1 MM)
VIEW ROTATED
LOOKING DOWN 2.68-2.74 INCH
(68.1-69.6 MM)
22
18 3
13
23 5
2
19 4
24
20 (10 PL)
21 (10 PL)
12 (REF)
14 (6 PL)

15 (6 PL)

26

28
4 (REF) 25
27

1 6 (4 PL)
29 7 (4 PL)

30 12 8
9
10 (10 PL)

5 (REF) 11 (10 PL)
32 24 (REF)
33
37 31
36
34
NOTES: 35
1. GASPER PLENUM SHOWN FOR HELICOPTER SERIAL NUMBER 900-00039 AND SUBSEQUENT OR
EARLIER SERIAL NUMBERS THAT HAVE COMPLETED SL900-035.
2. NUTS ARE INSTALLED ON HELICOPTER SERIAL NUMBER 900-00010 AND 900-00011 ONLY.
3. INSTALL TEMPERATURE PROBE APPROXIMATELY AS SHOWN. PROBE MUST BE 0.0 TO 0.2 INCH (0 TO 5.0 MM) BELOW
THE MATING SURFACE OF THE EVAPORATOR. 9G21050
Figure 405. Removal and Installation of the Evaporator (CURRENT CONFIG.)
Page 413

1. OUTLET SHROUD (REF. IPL, 215000, FIG. 2) 22. BAND CLAMP
2. BAND CLAMP 23. INLET SHROUD
3. EVAPORATOR TO DECK DUCT 24. TUBE
4. EXPANSION VALVE 25. TUBE
5. ADAPTER 26. EVAPORATOR INLET PORT
6. SCREW 27. WASHER
7. WASHER 28. SCREW
8. PACKING 29. WASHER
9. UNION
30. STRAINER
10. SCREW
31. CLAMP
11. WASHER
32. SENSE TUBE
12. EVAPORATOR
33. BAND CLAMP
13. GASKET
14. SCREW 34. SENSE ELEMENT
15. WASHER 35. RUBBER (C610)
16. NUT 36. GLASS FABRIC TAPE (C710)
17. GASPER PLENUM 37. NUT
18. FAN TO EVAPORATOR DUCT 38. SCREW
19. THERMOSTATIC SWITCH 39. WASHER
20. SCREW 40. NUT
21. WASHER 41. GROMMET
12. Evaporator Inlet Shroud (CURRENT (4). Install Access Panel T155 (ref. Section
CONFIG) 53-30-00).
A. Inlet Shroud Removal 13. Evaporator Assembly (CURRENT

CONFIG)
(Ref. Figure 405)
A. Evaporator Removal
(1). Remove Access Panel T155 (ref. Section
(Ref. Figure 405)
53-30-00).
(2). Remove band clamp (22). 12-00-00).
(3). Disconnect duct (18) from inlet shroud (2). Remove inlet shroud (23) (ref. Proce
(23). dure 12.A.).
(4). Remove screws (20) and washers (21). (3). Remove glass fabric tape (C710) (36)
and rubber (C610) (35) from sense
(5). Remove inlet shroud (23) and gasket element (34) and forward end of tube
(13). (25).
(4). Loosen clamp (33) and remove tempera

B. Inlet Shroud Installation ture sense element (34) from tube (25)
(Ref. Figure 405) (5). Disconnect tube (25).
(1). Install gasket (13), inlet shroud (23), (6). Remove union (9).
washers (21), and screws (20).
(7). Disconnect tube (24).
(a). Torque screws (20).
(8). Remove inlet adapter (5).
(2). Connect duct (18) to inlet shroud (23). (9). Remove screws (10) and washers (11).
(3). Install band clamp (22). (10). Remove evaporator (12) and gasket (8).
Page 414
B. Evaporator Installation (11). Wind glass fabric tape (C710) (36) on

rubber (C610) (35).
(Ref. Figure 405)
Consumable Materials pressor is removed, or the AC system is
(Ref. CSPSPM) opened. An early failure of the compressor
Item Nomenclature can occur.
C710 Tape, Glass Fabric
dehydrator (ref. Procedure 22.).
(1). Put evaporator (12) and gasket (8) in 12-00-00).
their installed position.
14. Evaporator Outlet Shroud (CURRENT
(2). Install washers (11) and screws (10). CONFIG)
(a). Torque screws (10) 20 to 25 in-lb A. Outlet Shroud Removal
(2.26 to 2.82 Nm).
(Ref. Figure 405)
(3). Install inlet shroud (23) (ref. Procedure
12.B.). (1). Remove evaporator (12) (ref. Procedure
13.A.).
(4). Install packing (8) and union (9) in the
outlet of evaporator (12). (2). Remove band clamp (22).
(3). Disconnect duct (18) from outlet shroud
(a). Torque union (9) 460 to 500 in-lb (1).
(51.97 to 56.49 Nm).
(5). Connect tube (25) to union (9).
(a). Torque the captive nut of tube (25) outlet shroud (1).
460 to 500 in-lb (51.97 to 56.49
Nm). B. Outlet Shroud Installation
(6). Make sure washer (29) and strainer (Ref. Figure 405)
(30) are installed in expansion valve
(4). Consumable Materials
(Ref. CSPSPM)
(7). Install adapter (5). Item Nomenclature
(a). Torque adapter (5) 230 to 260 in-lb C205 Sealing Compound
(25.99 to 29.38 Nm).
(8). Connect tube (24) to adapter (5). (1). Install outlet shroud (1), washers (7),
and screws (6).
(a). Torque the captive nut of tube (24) (a). Torque screws (6) 20 to 25 in-lb
230 to 260 in-lb (25.99 to 29.38 (2.26 to 2.82 Nm).
Nm).
(9). Put sense element (34) against tube
(25) at the 3 or 9 o'clock position, no
more than 12 inch (305 mm) along
tube (25) from the outlet of evaporator
(12). (2). Apply sealing compound (C205) to
mating surfaces, washers (7), and
(10). Put rubber (C610) (35) around sense screws (6).
element (34) and the full length of tube
(25). (3). Install screws (14) and washers (15).
Page 415
(a). Torque screws (14) 20 to 25 in-lb (3). Carefully straighten the temperature
(2.26 to 2.82 Nm). probe as you pull it through grommet
(41).
mating surfaces, washers (7, 15), and (4). Remove thermostatic switch (19).
screws (6, 14).
B. Thermostatic Switch Installation
(5). Connect duct (18) to outlet shroud (1).
(Ref. Figure 405)
(6). Install band clamp (22).
(1). Install thermostatic switch (19) with
(7). Install evaporator (12) (ref. Procedure screws (38), washers (39), and nuts
13.B.). (40).
15. Thermostatic Switch (CURRENT CONFIG) (a). Torque nuts (40) 20 to 25 in-lb (2.26
to 2.82 Nm).
A. Thermostatic Switch Removal
(2). Carefully pull the temperature probe
(Ref. Figure 405) thru grommet (41).
(1). Remove outlet shroud (1) (ref. Proce (3). Carefully bend the temperature probe
dure 14.A.). as shown (ref. Figure 405, Detail A).
(2). Remove nuts (40), screws (38), and (4). Install outlet shroud (1) (ref. Procedure
washers (39). 14.B.).
Page 416
Page 417
A411 J1 1
A412 J1
3 (P500)
2
10 4 (P501)
7
6
5
9 18
8
17
21
22
16
15
TUB (REF)
13
12
11 24
12
11
23
14
19
20
9G21-049
Figure 406. Removal and Installation of the Condenser (EARLY CONFIG)
Page 418

1. CONDENSER FAN 13. TUBE
2. VBAND CLAMP 14. TUBE
3. ELECTRICAL CONNECTOR P500 15. (POSTSB900012) SHIM
4. ELECTRICAL CONNECTOR P501 16. (POSTSB900012) CONDENSER SCOOP
5. WASHER 17. CONDENSER INLET SCREEN
6. SCREW 18. CONDENSER STAND
7. CONDENSER TRANSITION DUCT 19. WASHER
8. WASHER 20. SCREW
9. SCREW 21. CONDENSER EXIT SCREEN
10. CONDENSER 22. CONDENSER EXHAUST FRAME
11. PACKING 23. WASHER
12. UNION 24. SCREW
16. Condenser Fan (EARLY CONFIG) (a). Torque screws (6) 20 to 25 in-lb
(2.26 to 2.82 Nm).
A. Condenser Fan Removal
(2). Install condenser fans (1) (ref. Proce
(Ref. Figure 406) dure 16.B., Condenser Fan Installa
(1). Remove Access Panel A235 (ref. Section tion).
53-20-00). 18. Condenser (EARLY CONFIG)
(2). Disconnect Electrical Connector P500 A. Condenser Removal
or P501 (3, 4).
(Ref. Figure 406)
(3). Remove V-band clamp (2).
(4). Remove condenser fan (1). 12-00-00).
B. Condenser Fan Installation (2). Remove condenser transition duct (7)
(Ref. Figure 406) (ref. Procedure 17.A., Condenser
Transition Duct Removal).
(1). Install condenser fan (1) with V-band
clamp (2). (3). Disconnect tubes (13, 14) from unions
(12).
NOTE: As necessary, turn condenser fans (1) to
align with electrical connectors (3). (4). Remove unions (12) and packings (11).
(2). Connect Electrical Connector P500 or (a). Discard packings (11).

P501 (3, 4). (5). Remove screws (9), washers (8), and
(3). Install Access Panel A235 (ref. Section condenser (10).
53-20-00). B. Condenser Installation
17. Condenser Transition Duct (EARLY (Ref. Figure 406)
CONFIG)
(1). Install washers (8), screws (9), and
A. Condenser Transition Duct Removal condenser (10).
(1). Remove condenser fans (1) (ref. Proce (a). Torque screws (9) 20 to 25 in-lb
dure 16.A., Condenser Fan Removal). (2.26 to 2.82 Nm).
(2). Remove screws (6), washers (5), and (2). Install packings (11) on the condenser
duct (7). side of unions (12).
B. Condenser Transition Duct Installation (3). Install unions (12) with packings (11).
(1). Install washers (5), screws (6), and duct (a). Torque unions (12) 230 to 260 in-lb
(7). (25.99 to 29.38 Nm).
Page 419
(4). Connect tubes (13, 14) to unions (12). Sealing Compound (C205)
(a). Torque the captive nuts of tubes (13,

14) 230 to 260 in-lb (25.99 to 29.38
Nm).
(a). Install screws (20) wet with sealing
(5). Install condenser transition duct (7) compound (C205).
(ref. Procedure 17.B., Condenser
Transition Duct Installation). (b). Torque screws (20) 12 to 15 in-lb
(1.36 to 1.69 Nm) plus locking
The receiver dehydrator must torque.
CAUTION be replaced each time the com (3). Install condenser (10) (ref. Procedure
pressor is removed, or the AC system is 18.B., Condenser Installation).
can occur. 20. Condenser Exit Screen (EARLY CONFIG)
(6). Remove and replace the receiver A. Exit Screen Removal
(Ref. Figure 406)
(1). Remove Access Panel A235 (ref. Section
12-00-00).
53-20-00).
19. Condenser Inlet Screen (EARLY CONFIG) (2). Remove screws (24) and washers (23).
A. Inlet Screen Removal (3). Remove frame (22) and exit screen (21).
B. Exit Screen Installation
(Ref. Figure 406)
(Ref. Figure 406)
(1). Remove condenser (10) (ref. Procedure
18.A., Condenser Removal).
(Ref. CSPSPM)
(2). Remove screws (20) and washers (19). Item Nomenclature
(3). (Pre-SB900-012) Remove stand (18) C205 Sealing Compound

and inlet screen (17).
(1). Put exit screen (21) and frame (22) in
(Post-SB900-012) Remove stand (18), position for installation.
inlet screen (17), scoop (16), and spacer
(15). (2). Install washers (23) and screws (24).
B. Inlet Screen Installation Sealing Compound (C205)
(Ref. Figure 406)
(1). (Pre-SB900-012) Put inlet screen (17)

and stand (18) in position for installa (a). Install screws (24) wet with sealing
tion. compound (C205).
(b). Torque screws (24) 12 to 15 in-lb
(Post-SB900-012) Put shim (15), (1.36 to 1.69 Nm) plus locking
scoop (16), inlet screen (17), and stand torque.
(18) in position for installation.
(3). Install Access Panel A235 (ref. Section
(2). Install washers (19) and screws (20). 53-20-00).
Page 420
Page 421
1 (NOTE)
5 REF.
5
2
7
6
3 (3 PL)
4 (3 PL)
(NOTE)
8
9 (4 PL) VIEW ROTATED
10 (4 PL)
(NOTE)
17
11
12
13
12 14 (5 PL)
13 15 (5 PL)
17
LEFT CONDENSER SHOWN

RIGHT OPPOSITE
16
16
14 (5 PL) 15 (5 PL)
NOTE:
ONE ADDITIONAL WASHER CAN BE ADDED UNDER BOLT HEAD FOR CLEARANCE. 9G21043A
1. BOLT (REF. IPL, 632100, FIG. 2) 10. BOLT

2. WASHER 11. INLET COOLING DUCT
3. WASHER 12. BOLT
4. BOLT 13. WASHER
5. HEAT EXCHANGER 14. WASHER
6. CONDENSER 15. BOLT
7. INLET TUBE 16. HEAT EXCHANGER MOUNT
8. OUTLET TUBE 17. ELECTRICAL BOND JUMPER
9. WASHER
Figure 407. Removal and Installation of the Condenser (CURRENT CONFIG)
Page 422
21. Condenser (CURRENT CONFIG) (1). Prepare mating surfaces of electrical

bond jumper (17), condenser (6), and
A. Condenser Removal heat exchanger mount (16) for an
electrical bond (ref. CSP-SPM, Section
(Ref. Figure 407) 20-50-00).
NOTE: This task is typical for the left or right (2). Install condenser (6) on inlet cooling
condenser. duct (11) with washers (2) and bolts (1).
(1). Evacuate AC system (ref. Section (3). Put condenser (6) and inlet cooling duct
12-00-00). (11) between heat exchanger (5) and
heat exchanger mounts (16).
(2). Remove access panels T155 and T220
(ref. Section 53-30-00). (4). Install end of electrical bond jumper
(17) between inlet cooling duct (11) and
(3). Remove forward fairing support (ref. heat exchanger mount (16).
Section 53-30-00).
NOTE: If necessary, you can add one additional
Install plugs in tube nuts imme washer under the bolt head to get a clear
CAUTION diately after they are discon
ance between the bolt and condenser or the
nected. Unwanted material can get in tubes bolt and heat exchanger.
without plugs.
(5). Install bolts (12) and washers (13).
(4). Disconnect tubes (7, 8).
(a). Torque bolts (12) 36 to 46 in-lb
(5). Install plugs in tube nuts. (4.07 to 5.19 Nm).
NOTE: Be careful when you remove sealant Sealing Compound (C211)

from around electrical bond jumper (17).
(6). Remove bolts (15) and washers (14).

(6). Environmentally seal bolts (12) and
(8). Remove bolts (12) and washers (13). washers (13) with sealing compound
(C211) (ref. CSP-SPM, Section
(9). Remove bolts (4) and washers (3). 20-50-00).
(10). Remove condenser (6) and inlet cooling (7). Test the condenser for a Class H
duct (11). electrical bond (ref. CSP-SPM, Section
20-50-00).
(11). Remove bolt (1), washer (2), and
condenser (6). Sealant, Fuel Resistant (C216)
B. Condenser Installation
(Ref. Figure 407)
(8). Environmentally seal bolts (15) and
Consumable Materials electrical bond jumper (17) with sealant
(Ref. CSPSPM) (C216) (ref. CSP-SPM, Section
C211 Sealing Compound, Corrosion Inhibitive (9). Connect inlet tube (7) and outlet tube
C216 Sealant, Fuel Resistant (8).
(a). Torque captive nuts of tubes (7, 8)
NOTE: This task is typical for the left or right 230 to 260 in-lb (25.99 to 29.38
condensers. Nm).
Page 423
The receiver dehydrator must (11). Service AC system (ref. Section

CAUTION be replaced each time the com 12-00-00).
pressor is removed, or the AC system is
opened. An early failure of the compressor (12). Install forward fairing support (ref.
can occur. Section 53-30-00).
(10). Replace the receiver dehydrator (ref. (13). Install access panels T155 and T220
Procedure 22.). (ref. Section 53-30-00).
Page 424
Page 425
29
14 (2 PL) 1
15 (2 PL)
2
3
30 REF.
30 1
28 (2 PL) 31
TYPICAL 3 PL
27 2
26 REF.
3
26
22 REF. 21
23 (4 PL)
24 (4 PL) 1
24 19
25 22 20
14
15 8 8
16 8 3
1
18 2 4
17
13
12
1
11 2
11 5
EARLY CONFIG
3
8 2 4
1
4 8 1
5 2 TYPICAL
10
2 8
3
9 6
1
4
3 8
2
1
4
3 7
8 (2 PL)
TYPICAL
2
2 5
9G210061A
Figure 408. Removal and Installation of the Receiver Dehydrator
Page 426

1. RECEIVER DEHYDRATOR (REF. IPL, 215000, FIG. 1 7. TUBE (EARLY CONFIG.)
[EARLY CONFIG.] OR FIG. 2 [CURRENT CONFIG.]) 8. TUBE (CURRENT CONFIG.)
2. CLAMP 9. WASHER
3. GASKET (EARLY CONFIG.) 10. SCREW
4. ADAPTER (EARLY CONFIG.) 11. NUT
5. FLEXIBLE LINE (EARLY CONFIG.) 12. BRACKET
6. TUBE (CURRENT CONFIG.)
22. Receiver Dehydrator (3). Install clamps (2) on receiver dehydra

tor (1).
A. Receiver Dehydrator Removal
(a). Torque the captive screws of clamps
(Ref. Figure 408) (2) 18 in-lb (2.03 Nm).
(4). Install flare gaskets (3) and adapters
(4).
opened. An early failure of the compressor (a). Torque adapters (4) 230 to 260 in-lb
can occur. (25.99 to 29.37 Nm).
(1). EARLY CONFIG - Remove Access (5). EARLY CONFIG - Connect flexible
Panel R210 (ref. Section 53-30-00) line (5) and tube (7) to adapters (4).
CURRENT CONFIG - Remove Access
CURRENT CONFIG - Connect tubes
Panel L210 (ref. Section 53-30-00)
(6, 8) to adapters (4).
12-00-00). (a). Torque captive nuts of flexible line (5)
and tubes (5, 6, 8) 230 to 260 in-lb
(3). EARLY CONFIG - Disconnect tube (7) (25.99 to 29.37 Nm).
and flexible line (5).
CURRENT CONFIG - Disconnect 12-00-00).
tubes (6, 8).
(7). EARLY CONFIG - Install Access
(4). Remove adapters (4) and gaskets (3). Panel R210 (ref. Section 53-30-00).
(5). Remove clamps (2). CURRENT CONFIG - Install Access

Panel L210 (ref. Section 53-30-00).
(6). Remove receiver dehydrator (1).
23. Receiver Dehydrator Bracket
B. Receiver Dehydrator Installation
(Ref. Figure 408) A. Bracket Removal
The receiver dehydrator must (Ref. Figure 408)

pressor is removed, or the AC system is (1). Remove receiver dehydrator (1) (ref.
opened. An early failure of the compressor Procedure 22.A.).
can occur.
(2). Carefully remove sealant from bracket
(1). Install clamps (2) on bracket (12). (12), washers (9), and screws (10).
(2). Put receiver dehydrator (1) with clamps (3). Remove screws (10), washers (9), nuts
(2) on bracket (12). (11), and bracket (12).
Page 427
B. Bracket Installation Sealing Compound (C205)

(Ref. Figure 408)
(Ref. CSPSPM) (3). Environmentally seal between the
Item Nomenclature edges of bracket (12) and the upper
C205 Sealing Compound deck with sealing compound (C205) (ref.
(1). Put bracket (12) in position on the (4). Environmentally seal screws (10) and
upper deck. washers (9) with sealing compound
(2). Attach bracket (12) with washers (9), (C205) (ref. CSP-SPM, Section
screws (10), and nuts (11). 20-50-00).
(a). Torque screws (10) 20 to 25 in-lb (5). Install receiver dehydrator (1) (ref.
(2.26 to 2.82 Nm). Procedure 22.B.).
Page 428
29
14 (2 PL) 1
15 (2 PL)
2
3
30 REF.
30 1
28 (2 PL) 31
TYPICAL 3 PL
27 2
26 REF.
3
26
22 REF. 21
23 (4 PL)
24 (4 PL) 1
24 19
25 22 20
14
15 8 8
16 8 3
1
18 2 4
17
13
12
1
11 2
11 5
EARLY CONFIG
3
8 2 4
1
4 8 1
5 2 TYPICAL
10
2 8
3
9 6
1
4
3 8
2
1
4
3 7
8 (2 PL)
TYPICAL
2
2 5
9G210061A
Figure 409. AC System Installation (Sheet 1 of 2)
Page 429
66 50 26 REF.
67 45 REF. 34 REF.
32
14 (2 PL)
49
15 (2 PL)
33
68 34
HIGH PRESSURE 48 46 28 (2 PL)

SWITCH
47 (2 PL) 35
45
44
51
CURRENT CONFIG
36 51 52
8 37 (4 PL)
38 (4 PL) 52
17
14 43 38 (4 PL) 53
39 (4 PL)
42
54
40 53
13 LOW PRESSURE
41
15 (2 PL) 55 SWITCH
61
57
61 58
57 59
58 60
59 56
60 57
58
59
60
56
57
58
59
60 VIEW ROTATED
62 62
63 (3 PL) 63 (3 PL)
64 (2 PL) 64 (2 PL)
VIEW ROTATED 65 9G210062A
65
Figure 409. AC System Installation (Sheet 2 of 2)
Page 430

1. LOOP CLAMP 36. RECEIVER DEHYDRATOR BRACKET CURRENT
2. WASHER CONFIG
3. SCREW 37. SCREW
4. LOOP CLAMP 38. WASHER
5. NUT 39. NUT
6. TUBE 40. TUBE
7. TUBE 41. SIGHT GLASS
8. UNION 42. TUBE
9. TUBE 43. TUBE
10. TUBE 44. TUBE
11. TUBE 45. TUBE
12. TUBE 46. TUBE
13. UNION 47. TEE
14. ADAPTER 48. TUBE
15. FLARE GASKET 49. TUBE
16. TUBE 50. COMPRESSOR OUTLET HOSE CURRENT CONFIG
17. UNION 51. ELECTRICAL CONNECTOR P503
18. TUBE 52. LOWPRESSURE SWITCH
19. TUBE 53. PACKING
20. TUBE 54. FITTING
21. TUBE 55. TEE
22. TUBE 56. LOOP CLAMP
23. SCREW 57. SCREW
24. WASHER 58. LOOP CLAMP
25. NUT 59. WASHER
26. RECEIVER DEHYDRATOR 60. NUT
27. RECEIVER DEHYDRATOR BRACKET EARLY CONFIG 61. CLAMP
28. HOSE CLAMP 62. NUT
29. COMPRESSOR INLET HOSE EARLY CONFIG 63. WASHER
30. DECK TO RECEIVER DEHYDRATOR HOSE EARLY 64. WASHER
CONFIG 65. ELBOW
31. COMPRESSOR OUTLET HOSE EARLY CONFIG 66. ELECTRICAL CONNECTOR P502
32. COMPRESSOR INLET HOSE CURRENT CONFIG 67. HIGHPRESSURE SWITCH
33. TUBE 68. TEE
34. TUBE 69. LH CONDENSER
35. TUBE 70. RH CONDENSER
24. LowPressure Switch B. LowPressure Switch Installation

(Ref. Figure 409)
A. LowPressure Switch Removal
(1). Install low-pressure switch (52) with
new packing (53).
(Ref. Figure 409)
(2). Torque low-pressure switch (52) or the
nut of tee (55) 230 to 260 in-lb (25.99
(1). Open Access Panel R210 (ref. Section to 29.38 Nm).
06-00-00).
(3). Connect Electrical Connector P503
(2). Evacuate AC system (ref. Section (51).
12-00-00). The receiver dehydrator must
(3). Disconnect Electrical Connector P503 pressor is removed, or the AC system is
(51). opened. An early failure of the compressor
can occur.
(4). Remove low-pressure switch (52) and (4). Remove and replace the receiver
packing (53). dehydrator (ref. Procedure 22.).
(a). Discard packing (53). 12-00-00).
Page 431
(6). Close Access Panel R210 (ref. Section (4). Remove nut (5), screw (3), washers (2),
06-00-00). and loop clamp (4).
25. HighPressure Switch (5). Remove screws (57), washers (59), loop
clamps (56 and 58), nuts (60), and inlet
A. HighPressure Switch Removal hose (29 or 32).
(Ref. Figure 409) B. Inlet Hose Installation
(1). Open Access Panel R210 (ref. Section (Ref. Figure 409)
06-00-00).
(1). Connect inlet hose (29 or 32).
(2). Evacuate AC system (ref. Section (2). Install washers (2, 59), screws (3, 57),
12-00-00). loop clamps (4, 56, 58), and nuts (5, 60).
(3). Disconnect Electrical Connector P502 (a). Torque nuts.
(66).
(3). Torque the captive nuts of inlet hose
(4). Remove high-pressure switch (67). 460 to 500 in-lb (51.97 to 56.49 Nm).
B. HighPressure Switch Installation The receiver dehydrator must
(Ref. Figure 409) pressor is removed, or the AC system is
(1). Install high-pressure switch (67). opened. An early failure of the compressor
can occur.
(a). Torque the nut of tee 230 to 260
in-lb (25.99 to 29.38 Nm). (4). Remove and replace the receiver
(2). Connect Electrical Connector P502
(66).
12-00-00).
06-00-00).
opened. An early failure of the compressor 27. Compressor Outlet Hose
can occur.
A. Outlet Hose Removal
dehydrator (ref. Procedure 22.). (Ref. Figure 409)
(4). Service AC system (ref. Section (1). Disconnect outlet hose (31 or 50).
12-00-00). (2). Remove screws (57), washers (59),
(5). Close Access Panel R210 (ref. Section clamps (61 and 58), nuts (60), and inlet
06-00-00). hose (29 or 32).
B. Outlet Hose Installation
26. Compressor Inlet Hose
(Ref. Figure 409)
A. Inlet Hose Removal
(1). Connect outlet hose (31 or 50).
(Ref. Figure 409)
(2). Install clamps, screws, washers, and
(1). Open Access Panel R210 (ref. Section nuts.
06-00-00).
(a). Torque nuts.
12-00-00). (3). Torque the captive nuts of outlet hose
(31 or 50) 230 to 260 in-lb (25.99 to
(3). Disconnect inlet hose (29 or 32). 29.37 Nm).
Page 432
The receiver dehydrator must (6). Install access panels L155 and L210
CAUTION be replaced each time the com (ref. Section 53-30-00).
opened. An early failure of the compressor C. HighPressure Switch to MidSection
can occur. Tube Removal
(Ref. Figure 409)
dehydrator (ref. Procedure 22.). (1). Remove access panels L155, L210, and
R210 (ref. Section 53-30-00).
12-00-00). (2). Evacuate AC system (ref. Section
12-00-00).
06-00-00). (3). Disconnect tube (19) from union (8) and
tee (68).
28. HighPressure Tubes (EARLY CONFIG)
(4). Remove nuts (5), screws (3), washers
A. MidSection To Evaporator Tube (2), clamps (1), and tube (19).
Removal
D. HighPressure Switch to MidSection
(Ref. Figure 409) Tube Installation
(1). Remove access panels L155 and L210 (Ref. Figure 409)
(ref. Section 53-30-00). (1). Connect tube to union and tee.
(2). Evacuate AC system (ref. Section (2). Install clamps, screws, washers, and
12-00-00). nuts.
(3). Disconnect tube (16) from adapter (14) (a). Torque nuts.
and union (8).
(3). Torque tube nuts 230 to 260 in-lb
(4). Remove nuts (5), screws (3), washers (25.99 to 29.37 Nm).
(2), clamps (1), and tube (16).
CAUTION
B. MidSection To Evaporator Tube be replaced each time the com
Installation pressor is removed, or the AC system is
(Ref. Figure 409) can occur.
(1). Connect tube to adapter and union. (4). Remove and replace the receiver
(2). Install clamps, screws, washers, and
nuts. (5). Service AC system (ref. Section
12-00-00).
(a). Torque nuts.
(6). Install access panels L155, L210, and
(3). Torque tube nuts 230 to 260 in-lb R210 (ref. Section 53-30-00).
(25.99 to 29.37 Nm).
E. Receiver Dehydrator to HighPressure
The receiver dehydrator must Switch Tube Removal
pressor is removed, or the AC system is (Ref. Figure 409)
opened. An early failure of the compressor (1). Remove Access Panel R210 (ref. Section
can occur. 53-30-00).
(4). Remove and replace the receiver (2). Evacuate AC system (ref. Section
dehydrator (ref. Procedure 22.). 12-00-00).
(5). Service AC system (ref. Section (3). Remove tube (22) from tee (68) and
12-00-00). receiver dehydrator (26).
Page 433
F. Receiver Dehydrator to HighPressure (3). Torque hose nuts 230 to 260 in-lb
Switch Tube Installation (25.99 to 29.37 Nm).
(Ref. Figure 409) (4). Service AC system (ref. Section
12-00-00).
CAUTION be replaced each time the com (5). Install Access Panel R210 (ref. Section
pressor is removed, or the AC system is 53-30-00).
I. Baggage Closet to Deck Tube Removal
can occur.
(Ref. Figure 409)
dehydrator (ref. Procedure 22.). (1). Remove baggage compartment roof
insulation as necessary (ref. Section
(2). Connect tube to tee and receiver 25-00-00).
dehydrator.
(2). Remove baggage compartment right
(3). Torque tube nuts 230 to 260 in-lb insulation and closeout panel (ref.
(25.99 to 29.37 Nm). Section 25-00-00).
(4). Service AC system (ref. Section (3). Evacuate AC system (ref. Section
12-00-00). 12-00-00).
(5). Install Access Panel R210 (ref. Section (4). Disconnect tube (20) from elbow (65)
53-30-00). and union (8).
G. Receiver Dehydrator to Deck Hose (5). Remove screw (3), washer (2), and
Removal clamp (1). Remove tube (20).
(Ref. Figure 409) J. Baggage Closet to Deck Tube Installation
(1). Remove Access Panel R210 (ref. Section (Ref. Figure 409)
53-30-00).
(1). Connect tube to elbow and union.
(2). Evacuate AC system (ref. Section (2). Install clamp, screw, and washer.
12-00-00). Torque screw.
(3). Disconnect hose (30) from receiver (3). Torque tube nuts 230 to 260 in-lb
dehydrator (26) and elbow (65). (25.99 to 29.37 Nm).
(4). Remove hose (30). The receiver dehydrator must
H. Receiver Dehydrator to Deck Hose pressor is removed, or the AC system is
Installation opened. An early failure of the compressor
CAUTION be replaced each time the com dehydrator (ref. Procedure 22.).
pressor is removed, or the AC system is (5). Service AC system (ref. Section
opened. An early failure of the compressor 12-00-00).
can occur.
(6). Install baggage compartment right
(1). Remove and replace the receiver closeout panel and insulation (ref.
dehydrator (ref. Procedure 22.). Section 25-00-00).
(2). Connect hose to receiver dehydrator (7). Install baggage compartment roof
and elbow. insulation (ref. Section 25-00-00).
Page 434
K. Deck to Baggage Closet Tube Removal (2). Remove baggage compartment roof
insulation as necessary (ref. Section
(Ref. Figure 409) 25-00-00).
(1). Remove baggage compartment roof (3). Evacuate AC system (ref. Section
insulation as necessary (ref. Section 12-00-00).
25-00-00).
(4). Disconnect tube (20 or 21) from elbow
(2). Remove baggage compartment right (65).
insulation and closeout panel (ref.
Section 25-00-00). (5). Disconnect hose (30 or 31) from elbow
(65).
(3). Evacuate AC system (ref. Section (6). Remove nut (62), elbow (65), and
12-00-00). washers (63, 64).
(4). Disconnect tube (21) from elbow (65) N. Upper Deck Elbow Installation
and union (8).
(Ref. Figure 409)
(5). Remove screw (3), washer (2), clamp
(1), and tube (21). NOTE: Installation of upper deck elbow is typi
cal.
L. Deck to Baggage Closet Tube Installation
(1). Install washers (64) and two washers
(Ref. Figure 409) (63) on elbow.
(1). Connect tube to elbow and union. (2). Install elbow, washer (63), and nut.
(2). Install clamp, screw, and washer. (3). Torque nut 230 to 260 in-lb (25.99 to
29.37 Nm).
(a). Torque screw. (4). Connect tube and hose.
(3). Torque the captive nuts of tube 230 to (5). Torque tube and hose nuts 230 to 260
260 in-lb (25.99 to 29.37 Nm). in-lb (25.99 to 29.37 Nm).
The receiver dehydrator must The receiver dehydrator must
CAUTION be replaced each time the com CAUTION be replaced each time the com
pressor is removed, or the AC system is pressor is removed, or the AC system is
opened. An early failure of the compressor opened. An early failure of the compressor
can occur. can occur.
(4). Remove and replace the receiver (6). Remove and replace the receiver
dehydrator (ref. Procedure 22.). dehydrator (ref. Procedure 22.).
(5). Service AC system (ref. Section (7). Service AC system (ref. Section
12-00-00). 12-00-00).
(6). Install baggage compartment right (8). Install baggage compartment roof
closeout panel and insulation (ref. insulation (ref. Section 25-00-00).
Section 25-00-00). O. Baggage Closet Tube Removal
(7). Install baggage compartment roof (Ref. Figure 409)
insulation (ref. Section 25-00-00).
NOTE: Removal of forward or aft baggage clos
M. Upper Deck Elbow Removal et tube is the same.
(Ref. Figure 409) (1). Remove baggage compartment right
insulation and closeout panel (ref.
NOTE: Removal of upper deck elbow is typical. Section 25-00-00).
(1). Remove Access Panel R210 (ref. Section (2). Evacuate AC system (ref. Section
53-30-00). 12-00-00).
Page 435
(3). Disconnect tube (11) from unions (8). The receiver dehydrator must
(4). Remove screw (3), washer (2), and pressor is removed, or the AC system is
clamp (1). Remove tube (11). opened. An early failure of the compressor
can occur.
P. Baggage Closet Tube Installation
(Ref. Figure 409) dehydrator (ref. Procedure 22.).
NOTE: Installation of forward or aft baggage (4). Service AC system (ref. Section
closet tube is the same. 12-00-00).
(1). Connect tube to unions. (5). Install baggage compartment right
outboard floor panel (ref. Section
(2). Install clamp, screw, and washer. 53-20-00).
(a). Torque screw. S. Floor to Keel Beam Tube Removal
(3). Torque tube nuts 230 to 260 in-lb (Ref. Figure 409)
(25.99 to 29.37 Nm). (1). Remove baggage compartment right
The receiver dehydrator must outboard floor panel (ref. Section
pressor is removed, or the AC system is (2). Evacuate AC system (ref. Section
can occur.
(3). Disconnect tube (10) from unions (8).
dehydrator (ref. Procedure 22.). (4). Remove tube (10)
(5). Service AC system (ref. Section T. Floor to Keel Beam Tube Installation
12-00-00). (Ref. Figure 409)
(6). Install baggage compartment right (1). Connect tube (10) to unions (8).
closeout panel and insulation (ref.
Section 25-00-00). (a). Torque tube nuts 230 to 260 in-lb
(25.99 to 29.37 Nm).
Q. Keel Beam to Floor Tube Removal
(Ref. Figure 409)
(1). Remove baggage compartment right opened. An early failure of the compressor
outboard floor panel (ref. Section can occur.
53-20-00).
(2). Evacuate AC system (ref. Section dehydrator (ref. Procedure 22.).
12-00-00). (3). Service AC system (ref. Section
(3). Disconnect tube (9) from unions (8). 12-00-00).
Remove tube (9) (4). Install baggage compartment right
outboard floor panel (ref. Section
R. Keel Beam to Floor Tube Installation
53-20-00).
(Ref. Figure 409) U. Condenser to Keel Beam Tube Removal
(1). Connect tube to unions. (Ref. Figure 409)
(2). Torque tube nuts 230 to 260 in-lb (1). Remove baggage compartment floor
(25.99 to 29.37 Nm). center panel (ref. Section 53-20-00).
Page 436
(2). Evacuate AC system (ref. Section (4). Service AC system (ref. Section
12-00-00). 12-00-00).
(3). Disconnect tube (7) from unions (8). (5). Install baggage compartment floor
center panel (ref. Section 53-20-00).
(4). Remove tube (7)
29. HighPressure Tubes (CURRENT
V. Condenser to Keel Beam Tube CONFIG)
Installation
A. Evaporator to Sight Glass Tube Removal
(1). Connect tube to unions.
(Ref. Figure 409)
(2). Torque the captive nuts of tube 230 to
260 in-lb (25.99 to 29.37 Nm). (1). Remove Access Panel L155 (ref. Section
53-30-00).
CAUTION be replaced each time the com (2). Evacuate AC system (ref. Section
pressor is removed, or the AC system is 12-00-00).
(3). Remove tube (42) from sight glass (41)
can occur.
and adapter (14).
(3). Remove and replace the receiver B. Evaporator to Sight Glass Tube
dehydrator (ref. Procedure 22.). Installation
(4). Service AC system (ref. Section (Ref. Figure 409)
12-00-00).
(1). Install tube (42) between sight glass
(5). Install baggage compartment floor (41) and adapter (14).
(a). Torque the captive nuts of tube (42)
W. Keel Beam to Condenser Tube Removal 230 to 260 in-lb (25.99 to 29.37
Nm).
(Ref. Figure 409)
(1). Remove baggage compartment floor CAUTION be replaced each time the com
(2). Evacuate AC system (ref. Section opened. An early failure of the compressor
12-00-00). can occur.
(3). Remove tube (6) from unions (8). (2). Remove and replace receiver dehydra
tor (26) (ref. Procedure 22.).
X. Keel Beam to Condenser Tube
Installation (3). Service AC system (ref. Section
12-00-00).
(Ref. Figure 409)
(4). Install Access Panel L155 (ref. Section
(1). Connect tube to unions. 53-30-00).
(2). Torque tube nuts 230 to 260 in-lb C. Sight Glass Removal
(25.99 to 29.37 Nm). (Ref. Figure 409)
(1). Remove Access Panel L155 (ref. Section
53-30-00).
opened. An early failure of the compressor (2). Evacuate AC system (ref. Section
can occur. 12-00-00).
(3). Remove and replace the receiver (3). Disconnect tube (42) and tube (43) from
dehydrator (ref. Procedure 22.). sight glass (41).
Page 437
(4). Remove sight glass. The receiver dehydrator must

D. Sight Glass Installation pressor is removed, or the AC system is
(1). Install sight glass () between tubes (). (4). Remove and replace receiver dehydra
(2). Torque the captive nuts of tubes 230 to (5). Service AC system (ref. Section
260 in-lb (25.99 to 29.37 Nm). 12-00-00).
The receiver dehydrator must (6). Install Access Panel L155 (ref. Section
G. MidSection to Receiver Dehydrator
Tube Removal
can occur.
(Ref. Figure 409)
(3). Remove and replace receiver dehydra
tor (26) (ref. Procedure 22.). (1). Remove access panels L155 and L210
(4). Service AC system (ref. Section (2). Evacuate AC system (ref. Section
12-00-00). 12-00-00).
(5). Install Access Panel L155 (ref. Section (3). Disconnect tube (44) from union (8) and
53-30-00). receiver dehydrator (26).
(4). Remove tube.
E. Sight Glass to MidSection Tube
Removal H. MidSection to Receiver Dehydrator
Tube Installation
(Ref. Figure 409)
(Ref. Figure 409)
(1). Remove Access Panel L155 (ref. Section The receiver dehydrator must
53-30-00). CAUTION be replaced each time the com
(2). Evacuate AC system (ref. Section opened. An early failure of the compressor
12-00-00). can occur.
(3). Disconnect tube (43) from sight glass (1). Remove and replace receiver dehydra
(41) and union (8). tor (26) (ref. Procedure 22.).
(2). Connect mid section tube to receiver
(4). Remove screws (3), washers (2), clamps dehydrator to union and receiver
(1), washer (2), nut (5), and tube (43). dehydrator.
F. Sight Glass to MidSection Tube (3). Torque captive nuts of tube 230 to 260
Installation in-lb (25.99 to 29.38 Nm).

12-00-00).
(1). Connect tube to sight glass and union. (5). Install access panels L155 and L210
(2). Install screws, washers, clamps, and
nut. I. Receiver Dehydrator to Tee Tube
Removal
(a). Torque screws. (Ref. Figure 409)
(3). Torque captive nuts of tube 230 to 260 (1). Remove Access Panel L210 (ref. Section
in-lb (25.99 to 29.38 Nm). 53-30-00).
Page 438
(2). Evacuate AC system (ref. Section The receiver dehydrator must

(3). Disconnect receiver dehydrator to tee opened. An early failure of the compressor
tube (34) from receiver dehydrator (26) can occur.
and tee (47). Remove tube.
J. Receiver Dehydrator to Tee Tube
Installation (4). Service AC system (ref. Section
12-00-00).
(Ref. Figure 409) (5). Install Access Panel L210 (ref. Section
53-30-00).
CAUTION be replaced each time the com M. Right Condenser to Tee Tube Removal
pressor is removed, or the AC system is (Ref. Figure 409)
can occur. (1). Remove access panels L210 and R210
(1). Remove and replace receiver dehydra (2). Evacuate AC system (ref. Section
tor (26) (ref. Procedure 22.). 12-00-00).
(2). Connect tube to receiver dehydrator (3). Disconnect right condenser to tee tube
(26) and tee. (48) from tee (47) and RH condenser.
(4). Remove screws (3), washers (2), clamps
(3). Torque captive nuts of tube 230 to 260 (1), and tube.
in-lb (25.99 to 29.38 Nm).
N. Right Condenser to Tee Tube Installation
(4). Service AC system (ref. Section (Ref. Figure 409)
12-00-00).
(1). Connect right condenser to tee tube to
(5). Install Access Panel L210 (ref. Section tee and RH condenser.
53-30-00). (2). Install clamps, screws, and washers.
Torque screws.
K. Left Condenser to Tee Tube Removal
(3). Torque the captive nuts of tube 230 to
(Ref. Figure 409) 260 in-lb (25.99 to 29.38 Nm).
(1). Remove Access Panel L210 (ref. Section CAUTION be replaced each time the com
53-30-00). pressor is removed, or the AC system is
(2). Evacuate AC system (ref. Section can occur.
12-00-00).
(3). Remove tube (35) from tee (47) and LH tor (26) (ref. Procedure 22.).
condenser (69). (5). Service AC system (ref. Section
12-00-00).
L. Left Condenser to Tee Tube Installation
(6). Install access panels L210 and R210
(Ref. Figure 409) (ref. Section 53-30-00).
O. Left Condenser to HighPressure Switch
(1). Connect left condenser to tee tube to Tube Removal
tee and LH condenser (69).
(Ref. Figure 409)
(2). Torque tube nuts 230 to 260 in-lb (1). Remove access panels L210 and R210
(25.99 to 29.38 Nm). (ref. Section 53-30-00).
Page 439
(2). Evacuate AC system (ref. Section (a). Torque captive nuts of tube (46) 230
12-00-00). to 260 in-lb (25.99 to 29.38 Nm).
(3). Remove tube (45) from tee (68) and LH The receiver dehydrator must
condenser (69). CAUTION be replaced each time the com
(4). Remove screws (3), washers (2), clamps pressor is removed, or the AC system is
(1), and tube (45).
can occur.
P. Left Condenser to HighPressure Switch
Tube Installation (2). Remove and replace receiver dehydra
(Ref. Figure 409)
(1). Install tube (45) between tee (68) and 12-00-00).
LH condenser (69).
(2). Install clamps (1), screws (3), and (4). Install Access Panel R210 (ref. Section
washers (2). 53-30-00).
(a). Torque screws (3). S. Tee to Right Condenser Tube Removal
(3). Torque captive nuts of tube 230 to 260 (Ref. Figure 409)
in-lb (25.99 to 29.38 Nm).
(1). Remove Access Panel R210 (ref. Section
The receiver dehydrator must 53-30-00).
pressor is removed, or the AC system is (2). Evacuate AC system (ref. Section
can occur.
(3). Remove tube (49) from tee (47) and RH
condenser.
(5). Service AC system (ref. Section T. Tee to Right Condenser Tube Installation
12-00-00).
(Ref. Figure 409)
(6). Install access panels L210 and R210
(ref. Section 53-30-00). (1). Install tube (49) between tee (47) and
RH condenser.
Q. HighPressure Switch to Tee Tube
Removal (a). Torque the captive nuts of tube (49)
230 to 260 in-lb (25.99 to 29.38
(Ref. Figure 409) Nm).
(1). Remove Access Panel R210 (ref. Section
(2). Evacuate AC system (ref. Section pressor is removed, or the AC system is
12-00-00). opened. An early failure of the compressor
can occur.
(3). Remove tube (46) from tee (68) and tee
(47). (2). Remove and replace receiver dehydra
R. HighPressure Switch to Tee Tube
Installation
(Ref. Figure 409) 12-00-00).
(1). Connect high-pressure switch to tee (4). Install Access Panel R210 (ref. Section
tube (46) to tees (47, 68). 53-30-00).
Page 440
Page 441
1 (REF)
2 (REF)
3 (REF)
4 (REF)
5
16
17 6
7
8
9
5 (REF)
10
15
15 16 (REF) 6 (REF)
9 16 (REF) 6 (REF) 10
10
9
11
13 13
11
12 11
12 14
9G21047
Figure 410. Removal and Installation of LowPressure Lines (EARLY CONFIG)
Page 442

1. COMPRESSOR 10. CLAMP
2. RECEIVER DEHYDRATOR 11. WASHER
3. LOWPRESSURE SWITCH 12. NUT
4. TEE OR FITTING 13. BRACKET
5. TUBE (MIDSECTION TO LOWPRESSURE SWITCH) 14. BRACKET WITH LOCKNUT
6. TUBE (EVAPORATOR TO MIDSECTION) 15. CLAMP
7. UNION 16. LINE ASSEMBLY
8. PACKING 17. EVAPORATOR
9. SCREW
30. LowPressure Lines (EARLY CONFIG) (4). Attach clamp (10) to bracket (13) with
screw (9), washer (11), and nut (12).
A. ECS MidSection to LowPressure
Switch Tube Removal (a). Torque screw (9) 20 to 25 in-lb (2.26
to 2.82 Nm).
(Ref. Figure 410)
(5). Attach clamps (10, 15) to bracket (13)
(1). Remove the access panels L155, L210, with screw (9), washer (11), and nut
and R210 (ref. Section 53-30-00). (12).
(2). Evacuate AC system (ref. Section (a). Torque screw (9) 20 to 25 in-lb (2.26
12-00-00). to 2.82 Nm).
(6). Torque both captive nuts of tube (5) 460
(3). Disconnect tube (5) from union (7) and to 500 in-lb (51.97 to 56.49 Nm).
tee (4).
(4). Remove nuts (12), screws (9), washers CAUTION be replaced each time the com
(11), and clamps (10). pressor is removed, or the AC system is
(5). Remove tube (5). can occur.
B. ECS MidSection to LowPressure (7). Remove and replace receiver dehydra
Switch Tube Installation tor (2) (ref. Procedure 22.).
12-00-00).
Consumable Materials (9). Install access panels L155, L210, and
(Ref. CSPSPM) R210 (ref. Section 53-30-00).
Item Nomenclature
C. ECS Evaporator To MidSection Tube
Removal
(Ref. Figure 410)
(1). If tube (5) is a replacement, do these (1). Remove access panels L155 and L210
steps: (ref. Section 53-30-00).
(a). Wind rubber (C610) on surface of (2). Evacuate AC system (ref. Section
tube (5). 12-00-00).
(3). Remove glass fabric tape (C710) and
(b). Wind glass fabric tape (C710) on rubber (C610) from forward 12 inch
rubber (C610). (305 mm) of tube (6).
(2). Connect tube (5) to union (7) and tee (4). Disconnect tube (6) from unions (7).
(4).
(3). Install clamps (10) on tube (5). (11), and clamps (10).
Page 443
(6). Remove tube (6). (3). Connect tube (6) to unions (7).
(7). If necessary, remove union (7) and
(4). Install clamps (10) on tube (6).
packing (8) from evaporator (17).
(a). Discard packing (8). (5). Attach clamps (10, 15) to bracket (13)
with washer (11) and screw (9).
D. ECS Evaporator To MidSection Tube
Installation
(a). Torque screw (9) 20 to 25 in-lb (2.26
(Ref. Figure 410) to 2.82 Nm).

(Ref. CSPSPM)
Item Nomenclature
(a). Torque screw (9) 20 to 25 in-lb (2.26
C610 Rubber, Expanded to 2.82 Nm).
(1). If removed, install union (7) on evapo to 500 in-lb (51.97 to 56.49 Nm).
rator (17):
(8). Wind rubber (C610) on forward 12 inch
(a). Install packing (8) on evaporator (17) (305 mm) surface of tube (6).
side of union (7).
(b). Install union (7) with packing (8) on (9). Wind glass fabric tape (C710) on rubber
evaporator (17). (C610).
(c). Torque union (7) 460 to 500 in-lb The receiver dehydrator must
(51.97 to 56.49 Nm). CAUTION be replaced each time the com
(2). If tube (6) is a replacement, do these
steps:
can occur.
(a). Wind rubber (C610) on surface of
tube (6) from 12 inch (305 mm) aft (10). Remove and replace receiver dehydra
of forward end to aft end. tor (2) (ref. Procedure 22.).
(b). Wind glass fabric tape (C710) on
rubber (C610).
12-00-00).
NOTE: Do not put glass fabric tape (C710) on
forward 1.00 inch (25.4 mm) of rubber (12). Install access panels L155 and L210
(C610). (ref. Section 53-30-00).
Page 444
Page 445
1 (REF)
2 (REF)
6
4 (REF)
5 (REF)
3 (REF)
17 (REF)
7 8
18
8
9
10
12
6 (REF)
11
6 (REF)
11
10
12
14
12
13
15
16
17 (REF) 7 (REF) 16
11 10 12 17 (REF) 7 (REF)
11
10
12
14
15 12
13
9G21048
Figure 411. Removal and Installation of LowPressure Lines (CURRENT CONFIG)
Page 446

1. COMPRESSOR 10. SCREW
2. LOWPRESSURE SWITCH 11. CLAMP
3. FITTING 12. WASHER
4. RECEIVER DEHYDRATOR 13. NUT
5. LH CONDENSER 14. BRACKET
6. TUBE (MIDSECTION TO LOWPRESSURE SWITCH) 15. BRACKET WITH LOCKNUT
7. TUBE (EVAPORATOR TO MIDSECTION) 16. CLAMP
8. UNION 17. TUBE
9. PACKING 18. EVAPORATOR
31. LowPressure Lines (CURRENT CONFIG) (4). Attach clamp (11) to bracket (14) with
screw (10), washers (12), and nut (13).
A. ECS MidSection to LowPressure
Switch Tube Removal (a). Torque screw (10) 20 to 25 in-lb
(2.26 to 2.82 Nm).
(Ref. Figure 411)
(5). Attach clamp (11) to bracket (15) with
(1). Remove the access panels L155, L210, washer (12), and screw (10).
and R210 (ref. Section 53-30-00).
(a). Torque screw (10) 20 to 25 in-lb
(2). Evacuate AC system (ref. Section (2.26 to 2.82 Nm).
12-00-00).
(3). Disconnect tube (6) from union (8) and to 500 in-lb (51.97 to 56.49 Nm).
tee (4). The receiver dehydrator must
(12), and clamps (11). pressor is removed, or the AC system is
(5). Remove tube (6). can occur.
B. ECS MidSection to LowPressure (7). Remove and replace receiver dehydra

Switch Tube Installation tor (4) (ref. Procedure 22.).

12-00-00).
Consumable Materials (9). Install access panels L155, L210, and

(Ref. CSPSPM) R210 (ref. Section 53-30-00).
Item Nomenclature C. ECS Evaporator To MidSection Tube
C610 Rubber, Expanded Removal
(Ref. Figure 411)
(1). Remove access panels L155 and L210
(1). If tube (6) is a replacement, do these
steps:
(a). Wind rubber (C610) on surface of 12-00-00).
tube (5).
(3). Remove glass fabric tape (C710) and
(b). Wind glass fabric tape (C710) on rubber (C610) from forward 12 inch
rubber (C610). (305 mm) of tube (7).
(2). Connect tube (6) to union (8) and tee (4). Disconnect tube (7) from unions (8).
(3).
(3). Install clamps (11) on tube (6) (12), and clamps (11).
Page 447
(6). Remove tube (7). (3). Connect tube (7) to unions (8).
(7). If necessary, remove union (8) and (4). Install clamps (11) on tube (7)
packing (9) from evaporator (18).
(a). Discard packing (9). (5). Attach clamps (11, 16) to bracket (15)
D. ECS Evaporator To MidSection Tube
Installation (a). Torque screw (10) 20 to 25 in-lb
(Ref. Figure 411) (2.26 to 2.82 Nm).

Consumable Materials with screw (10), washer (12), and nut
(Ref. CSPSPM) (13).
Item Nomenclature
C610 Rubber, Expanded (a). Torque screw (10) 20 to 25 in-lb
C710 Tape, Glass Fabric (2.26 to 2.82 Nm).

(1). If removed, install union (8) on evapo to 500 in-lb (51.97 to 56.49 Nm).
rator (18):
(a). Install packing (9) on evaporator (18) (8). Wind rubber (C610) on forward 12 inch
side of union (8). (305 mm) surface of tube (7).
(b). Install union (8) with packing (9) on (9). Wind glass fabric tape (C710) on rubber
evaporator (18). (C610).
(c). Torque union (8) 460 to 500 in-lb
(51.97 to 56.49 Nm). CAUTION be replaced each time the com
(2). If tube (7) is a replacement, do these pressor is removed, or the AC system is
steps: opened. An early failure of the compressor
can occur.
(a). Wind rubber (C610) on surface of
tube (7) from 12 inch (305 mm) aft (10). Remove and replace receiver dehydra
of forward end to aft end. tor (4) (ref. Procedure 22.).
(b). Wind glass fabric tape (C710) on
rubber (C610). (11). Service AC system (ref. Section
12-00-00).
NOTE: Do not put glass fabric tape (C710) on
forward 1.00 inch (25.4 mm) of rubber (12). Install access panels L155 and L210
(C610). (ref. Section 53-30-00).
Page 448
AIR CONDITIONING SYSTEM

INSPECTION/TEST
1. Air Conditioning System Inspection (2). Inspect high pressure switch for
serviceable condition. Repair or replace
A. Freon Compressor Inspection as necessary.
(1). Inspect compressor for security. Repair E. Low Pressure Switch Inspection
or replace as necessary.
(1). Inspect low pressure switch for corro
(2). Inspect compressor for cracks at engine sion. None permitted.
mount pad attachments. None permit (2). Inspect low pressure switch for service
ted. able condition. Repair or replace as
necessary.
(3). Inspect compressor drive reduction gear
box site glass for proper oil level F. Evaporator Fan Inspection
(1). Inspect evaporator fan for damage at
B. Receiver Dehydrator Inspection mount flanges. None permitted.
(1). Inspect receiver dehydrator for service (2). Inspect for cracks and corrosion. None
able condition. Repair or replace as permitted.
necessary.
(3). Inspect for loose or missing hardware.
(2). Inspect receiver dehydrator for corro Repair or replace as necessary.
sion. None permitted. (4). Inspect V-band clamp for security.
(3). Inspect fittings for evidence of leakage.
None permitted. G. Three Way Valve Duct Assembly
Inspection
C. Evaporator Assembly Inspection
(1). Inspect three way valve for serviceable
(1). Inspect evaporator for damage of condition and for freedom of operation.
evaporator fins and tubes. None Repair or replace as necessary.
permitted.
(2). Inspect for cracks at mount flange. Repair or replace as necessary.
None permitted.
(3). Inspect for cracks, deformation and
(3). Inspect fan shroud for cracks, deforma deterioration. None permitted.
tion and deterioration. None permitted. H. Three Way Valve Control Cable
Inspection
Repair or replace as necessary. (1). Inspect control cable for serviceable
condition and freedom of operation.
D. High Pressure Switch Inspection Repair or replace as necessary.
(1). Inspect high pressure switch for (2). Inspect for loose or missing hardware.
corrosion. None permitted. Repair or replace as necessary.
Page 601
21-50-00 Revision 8
I. Line and Tube Assemblies Inspection (4). Inspect attach fitting for evidence of
leakage.
(1). Inspect low pressure line for serviceable
condition of insulation material from (a). If leakage has occurred evacuate
evaporator to low pressure switch. No system.
damage permitted. (b). Remove, repair or replace leaking or
non-serviceable fittings.
(2). Inspect lines, tubes and fittings for
evidence of leakage and serviceable (c). Service air conditioning system
condition. (Ref. Section 12-00-00).
K. Condenser Fan Inspection
(a). If leakage has occurred evacuate (EARLY CONFIG)
system.
(1). Inspect condenser fan for visible
(b). Remove, repair or replace leaking or corrosion. No damage permitted.
non-serviceable condition lines,
tubes and fittings. (2). Inspect for loose or missing hardware.
(c). Service air conditioning system (3). Inspect fan shroud for cracks, deforma
(Ref. Section 12-00-00). tion and deterioration. No damage
permitted.
(3). Inspect for loose or missing attachment
support hardware. Repair or replace as (4). Verify condenser fan operation.
necessary. L. Condenser Scoop
(EARLY CONFIG)
J. Condenser Assembly Inspection
(1). Inspect condenser scoop for cracks.
(1). Inspect condenser for damage at mount None permitted.
flange. None permitted.
(2). Inspect condenser scoop for loose or
missing attachment hardware. Repair
(2). Inspect for cracks. None permitted. or replace as necessary.
(3). Inspect for loose or missing hardware. (3). Inspect for deformation and deteriora
Repair or replace as necessary. tion. Repair or replace as necessary.
Page 602
Revision 8 21-50-00
Chapter
EQUIPMENT /
FURNISHINGS
TABLE OF CONTENTS
25-10-00 Crew Compartment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A

1. Equipment / Furnishings - General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Crew Compartment Interior . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
A. Crew Seats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
B. Five-Point Restraint System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
C. Seat Cushions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Figure 1.Crew Seat Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Figure 2.Crew Compartment Interior/Trim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Fault Isolation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
1. Interior Assemblies Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Table 101.Seat Assemblies Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
1. Crew Seat Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
A. Crew Seat Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
B. Crew Seat Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
2. Seat Cushions, Back Rest and Pan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
A. Seat Cushion Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
B. Seat Cushion Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
3. Restraint System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
A. Restraint System (Harness) Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
B. Restraint System (Harness) Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
4. Adjustment Rail Assembly, Crew Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 402
A. Adjustment Rail Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 402
B. Adjustment Rail Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 402
5. Seat Back Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 402
A. Seat Back Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 402
B. Seat Back Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 402
6. Seat Pan Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 403
A. Seat Pan Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 403
B. Seat Pan Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 403
7. Upright Support Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 403
A. Upright Support Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 403
B. Upright Support Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 403
8. Cable Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 403
A. Cable Roller Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 403
Page i
25 Contents Original

B. Cable Roller Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 404
9. Lock System Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 404
A. Lock System Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 404
B. Lock System Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 404
10. Diagonal Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 404
A. Diagonal Support Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 404
B. Diagonal Support Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 404
11. Aft Rail Holder Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 404
A. Aft Rail Holder Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 404
B. Aft Rail Holder Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 405
12. Forward Rail Holder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 405
A. Forward Rail Holder Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 405
B. Forward Rail Holder Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 405
13. Forward Roller Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 405
A. Forward Roller Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 405
B. Forward Roller Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 405
14. Aft Roller Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 406
A. Aft Roller Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 406
B. Aft Roller Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 406
15. Side Tube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 406
A. Side Tube Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 406
B. Side Tube Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 406
16. Tie Tube Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 406
A. Tie Tube Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 406
B. Tie Tube Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 406
17. Attenuation Tube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 407
A. Attenuation Tube Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 407
B. Attenuation Tube Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 407
18. Fixed Fitting Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 407
A. Fixed Fitting Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 407
B. Fixed Fitting Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 407
Figure 401.Crew Seat Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 408
19. General (Soft) Insulation Panel Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 409
A. Insulation Panel Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 409
B. Insulation Panel Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 409
20. Coat Hook . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 409
Page ii

A. Coat Hook Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 409
B. Coat Hook Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 409
21. Area Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 409
A. Area Light Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 409
B. Area Light Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 410
22. Cockpit Utility Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 410
A. Cockpit Utility Light Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 410
B. Cockpit Utility Light Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 410
23. Controls Closet Panel, Inboard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 410
A. Controls Closet Panel, Inboard Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 410
B. Controls Closet Panel, Inboard Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 410
24. Carpet Trapping Strip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 410
A. Carpet Trapping Strip Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 410
B. Carpet Trapping Strip Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 410
25. Carpet - Cockpit Floor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 410
A. Carpet Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 410
B. Carpet Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 410
26. Lower Panel, Left Hand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 410
A. Lower Panel, Left Hand Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 410
B. Lower Panel, Left Hand Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 410
27. Top Panel Assembly - Left Hand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 411
A. Top Panel Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 411
B. Top Panel Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 411
28. Lower Panel, Right Hand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 411
A. Lower Panel, Right Hand Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 411
B. Lower Panel, Right Hand Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 411
29. Side Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 411
A. Side Panel Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 411
B. Side Panel Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 411
30. Main Covers, Center Beam, LH and RH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 411
A. Main Covers, Center Beam Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 411
B. Main Covers, Center Beam Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 411
31. Forward Cover, Center Beam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 411
A. Forward Cover, Center Beam Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 411
B. Forward Cover, Center Beam Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 411
32. Top Panel Assembly - Right Hand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 411
Page iii

A. Top Panel Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 411
B. Top Panel Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 411
33. Roof Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 412
A. Roof Panel Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 412
B. Roof Panel Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 412
34. In-Fill Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 412
A. In-Fill Panel Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 412
B. In-Fill Panel Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 412
35. Door Panel, Cockpit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 412
A. Door Panel Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 412
B. Door Panel Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 412
36. Support, Headset Jack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 412
A. Support, Headset Jack Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 412
B. Support, Headset Jack Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 412
Figure 402.Crew Compartment Interior Trim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 413
Inspection/Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601
1. Crew Compartment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601
A. Seat Inspection (Area 1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601
B. Seat Energy Absorption System (EAS) Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . 601
Figure 601.Seat EAS Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 602
C. Seat Restraint System Inspection
(Area 1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 602
D. Trim Inspection (Area 1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 603
E. Seat Operational Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 603
F. Seat Restraint System Operational Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 603
25-20-00 Cabin Compartment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A
1. Equipment / Furnishings - General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Cabin Compartment Equipment / Furnishings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
A. Cabin Seats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
B. Restraint System - Cabin Seats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
C. Tie Downs - Cabin Compartment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Figure 1.Cabin Seat Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Figure 2.Cabin Interior/Trim - Commercial/Business (Sheet 1 of 2) . . . . . . . . . . 3
Figure 3.Cabin Interior/Trim - Utility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Fault Isolation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
1. Interior Assemblies Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Page iv


1. Cabin Seat Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
A. Cabin Seat Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
B. Cabin Seat Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
2. Restraint System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
A. Restraint System Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
B. Restraint System Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
3. Cabin Seat Fabric Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
A. Cabin Seat Fabric Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
B. Cabin Seat Fabric Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
Figure 401.Cabin Seats/Restraint System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 402
Figure 402.Cabin Seat Fabric Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 402
4. Insulation (Wall) Panels (Commercial and Utility) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 403
5. Wall Panels (902 CONFIG) (Business) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 403
A. Wall Panel Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 403
B. Wall Panel Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 403
6. Acoustic Insulation (Roof) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 403
A. Acoustic Insulation Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 403
B. Acoustic Insulation Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 403
7. Cabin Carpet (Commercial and Business) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 403
A. Cabin Carpet Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 403
B. Cabin Carpet Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 403
8. Forward and Aft Roof Panels (Commercial and Business) . . . . . . . . . . . . . . . . . . . . . 404
A. Forward and Aft Roof Panels Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 404
B. Forward and Aft Roof Panels Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 404
9. Center Roof Panel (Commercial and Business) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 404
A. Center Roof Panel Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 404
B. Center Roof Panel Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 404
10. Area Light, Cabin Roof . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 404
11. Light Support Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 404
A. Light Support Plate Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 404
B. Light Support Plate Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 404
Page v

12. Light Support Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 405
A. Light Support Units Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 405
B. Light Support Units Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 405
13. Passenger Service Unit (PSU) Panels, Forward and Aft (Commercial and Business) . . . . . .
405
A. PSU Panels Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 405
B. PSU Panels Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 405
14. Soundproofing (902 CONFIG) (Business) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 405
A. Soundproofing Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 405
B. Soundproofing Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 405
15. Closeout Panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 405
A. Closeout Panels Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 405
B. Closeout Panels Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 406
16. Door Panel and Trapping Strip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 406
A. Door Panel and Trapping Strip Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 406
B. Door Panel and Trapping Strip Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 406
17. Window Reveal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 406
A. Window Reveal Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 406
B. Window Reveal Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 406
Figure 403.Cabin Compartment Interior Trim - Commercial/Business . . . . . . . 407
18. Cabin Carpet (Utility) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 408
A. Cabin Carpet Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 408
B. Cabin Carpet Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 408
19. Roof Panel (Utility) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 408
A. Roof Panel Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 408
B. Roof Panel Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 408
20. Area Light, Cabin Roof . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 408
21. Light Support Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 408
A. Light Support Plate Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 408
B. Light Support Plate Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 409
22. Closeout Panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 409
23. Door Panel and Trapping Strip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 409
A. Door Panel and Trapping Strip Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 409
Page vi

B. Door Panel and Trapping Strip Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 409
Figure 404.Cabin Compartment Interior Trim - Utility . . . . . . . . . . . . . . . . . . . . . 410
Inspection/Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601
1. Cabin Compartment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601
A. Seat Inspection (Area 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601
B. Seat Energy Absorption System (EAS) Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . 601
C. Seat Restraint System Inspection
(Area 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601
Figure 601.Seat EAS Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 602
D. Trim Inspection (Area 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 603
E. Seat Operational Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 603
F. Seat Restraint System Operational Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 603
25-50-00 Baggage Compartment Interior Trim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A
1. Baggage Compartment Interior . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Figure 1.Baggage Compartment Interior Trim (Sheet 1 of 2) . . . . . . . . . . . . . . . . 2
Fault Isolation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
1. Interior Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
1. Insulation Panel (Trim) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
2. Closeout Panel Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
3. Carpet Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
A. Carpet Panel Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
B. Carpet Panel Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
4. Area Light Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
A. Area Light Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
B. Area Light Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 402
5. Door Trim Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 402
A. Door Trim Panel Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 402
B. Door Trim Panel Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 402
6. Soundproofing Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 402
Page vii

A. Soundproofing Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 402
B. Soundproofing Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 402
Figure 401.Baggage Compartment Interior Trim/Soundproofing . . . . . . . . . . . . . 403
Inspection / Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601
1. Interior Trim Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601
25-55-00 Cargo Hook System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A
1. Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Figure 1.Cargo Hook System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Fault Isolation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
1. Cargo Hook System Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Table 101.Cargo Hook System Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
1. Cargo Hook System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
A. Cargo Hook System Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
B. Cargo Hook Detachment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
C. Cargo Hook Reattachment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
D. Cargo Hook System Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
Figure 401.Cargo Hook System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 402
2. Cargo Hook Cockpit, Mechanical Release Cable Assembly . . . . . . . . . . . . . . . . . . . . . 403
A. Cargo Hook Cockpit, Mechanical Release Cable Assembly Removal . . . . . . . . . . 403
B. Cargo Hook Cockpit, Mechanical Release Cable Assembly Installation . . . . . . . 403
3. Cargo Hook Cockpit, Mechanical Release Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . 403
A. Cargo Hook Cockpit, Mechanical Release Bracket Removal . . . . . . . . . . . . . . . . . . 403
B. Cargo Hook Cockpit, Mechanical Release Bracket Installation . . . . . . . . . . . . . . . 403
4. Cable Support Clip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 403
A. Cable Support Clip Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 403
B. Cable Support Clip Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 403
Figure 402.Cargo Hook Mechanical Release . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 404
5. Cargo Hook, Wire Harness - W314 Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 405
A. Wire Harness - W314 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 405
B. Wire Harness - W314, Initial Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 405
Figure 403.Wire Harness - W314, Cargo Hook . . . . . . . . . . . . . . . . . . . . . . . . . . . . 406
Inspection / Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601
1. Cargo Hook System Inspections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601
Page viii

A. General Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601
B. Cargo Hook Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601
Figure 601.Aft Saddle Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 602
C. Inspection for the Aft LH and Aft RH Saddle Assemblies . . . . . . . . . . . . . . . . . . . . 603
Figure 602.Cargo Hook Cable Measurements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 604
D. Cable (Wire Rope) Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 605
2. Cargo Hook System Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 605
A. Cargo Hook System Functional Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 605
B. Cargo Hook System Operational Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 606
25-60-00 Emergency Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A
1. Emergency First Aid Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
A. First Aid Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
B. First Aid Kit Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1. First Aid Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
A. First Aid Kit Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
25-60-10 Rescue Hoist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A
1. Rescue Hoist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
A. Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
B. Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1. Rescue Hoist Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
A. Install Hoist, Support And Strut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
Figure 1.Hoist System Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
B. Assist Handel Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
C. Fairing Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
Figure 2.Hoist Fairing Installation) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
2. Guard Installation, RH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
A. Skid Guard Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
Figure 3.Landing Gear Skid Guard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
B. Float Guard Installation, Rescue Hoist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
Figure 4.Float Guard Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
C. Assist Handle Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
D. Fairing Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
Page ix

E. Hoist Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
F. Skid Guard Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
G. Float Guard Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208
1. Servicing Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 301
A. Hoist Fluid Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 301
Figure 1.Fluid Level Sight Gauge Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 301
Table 1.Servicing Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 302
Inspection / Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601
1. Rescue Hoist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601
A. Hoist System Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601
B. Electrical System Functional Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 801
1. Repair Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 801
25-70-00 Hinged Avionics Shelf . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A
1. Hinged Avionics Shelf . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Figure 1.Hinged Avionics Shelf . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
A. Hinged Avionics Shelf Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
B. Hinged Avionics Shelf Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
2. Avionics Shelf Channel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
A. Avionics Shelf Channel Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
B. Avionics Shelf Channel Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
3. Support Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
A. Support Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
B. Support Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
Figure 201.Hinged Avionics Shelf . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
A. Hinged Avionics Shelf Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
Page x
Section
251000
Crew Compartment

CREW COMPARTMENT INTERIOR

1. Equipment / Furnishings General with seven positions. The seat adjustment
controls are located at the center of the seat.
The standard equipment and furnishings During fore and aft adjustment of the seat, the
provide seating for the pilot, copilot, and six automatic tilting feature tilts the seat back
passengers. Each crew and cabin seat is from 18 degrees in the fore most position, to 20
equipped with a restraint system. The basic degrees in the rear most position.
furnishings include interior trim, acoustic
insulation, floor coverings, and other miscella The seat assemblies are comprised of a formed
neous items for furnishing of the helicopter tubular structure, sheet metal seat pan with
interior. removeable cushion, and a fabric seat back
with cushion. Incorporated in the frame are
Each, will be described separately relating to energy absorbers that initiate stroking of the
their compartment. seat when severe vertical loads are applied to
the seat assembly. Because of this feature, No
2. Crew Compartment Interior stowage under seats is allowed. Each crew
seat has a minimum available stroking
(Ref. Figure 1 and Figure 2) distance of 7 inches.
The equipment and furnishings provided in

B. FivePoint Restraint System
the crew compartment include two energy
attenuating crew seats with quick release
five-point restraint systems and seat cushions, The crew seats are equipped with a five-point
single or dual pilot main instrument panel, restraint system that combines a lap safety
area light, detachable utility light, 28 Vdc belt, tie-down strap and double strap shoulder
utility outlet and cockpit trim. harness with a manual locking inertia reel.
The restraint straps are fabricated from
A. Crew Seats polyester webbing with sewn in buckles and
attach fittings.
(Ref. Figure 1)
The inertia reel also provides the pilot or
The crew seats are interchangeable, with fore copilot with the ability to manually lock the
and aft adjustment, automatic tilting mecha inertia reel. The inertia reel lock handle can be
nism and energy attenuating structure, moved to release the reel and provide free
five-point restraint system, and upper and movement of the shoulder harness. An
lower seat cushions. adjuster on each shoulder harness permits the
pilot or copilot to adjust the tension of the
The crew seats are located in the crew shoulder harness. The lap belts also have an
compartment. The pilot seat is located on the adjustment feature.
right side of the crew compartment, the
co-pilot seat is located on the left. Each seat
will comfortably accommodate an occupant C. Seat Cushions
ranging from a 25th percentile woman to a
95th percentile man. Each crew seat is equipped with a seat back
and seat pan cushion. The seat materials
The seat structures attach to the crew comply with FAR 29.853 (B) vertical burn
compartment floor and subfloor structure. requirements. Velcro strips secure the seat
cushions to the seat pan. The seat back
Each crew seat has a combined vertical and cushion is incorporated into the seat back
horizontal fore and aft adjustment of 3 inches, fabric and is secured with a laced cord.
Page 1
25-10-00 Original
RESTRAINT
SYSTEM
ATTENUATION
TUBES
9G25001
Figure 1. Crew Seat Assemblies
Page 2
Original 25-10-00
TOP PANEL
ROOF PANEL
CENTER
BEAM COVER
HOOK TAPE
HOOK TAPE
COAT HOOK
TOP PANEL
ASSEMBLY
LIGHT ASSEMBLIES
CENTER BEAM
COVER
COAT
CLOSET PANEL
HOOK
ASSEMBLIES
INTERIOR
DOOR PANEL
LOWER
PANEL
ASSEMBLY
SIDE PANEL
ASSEMBLY
CARPET PANEL
CARPET
TRAPPING
CARPET STRIP
PANEL
HOOK TAPE
CARPET TRAPPING
STRIP 9G25002A
Figure 2. Crew Compartment Interior/Trim
Page 3/(4 blank)

25-10-00 Original

FAULT ISOLATION
1. Interior Assemblies Troubleshooting Troubleshooting tables should be used with the
simplified system schematics, electrical wiring
The following troubleshooting procedures are a diagrams, serviceability checks and other
brief summary of seat assemblies faults, which detailed procedures referred to in this and
may be encountered (Ref. Table 101). other chapters of the manual.
Table 101. Seat Assemblies Troubleshooting
Crew seat does not adjust Malfunction of seat Localize damaged components 251000
forward or aft. adjustment lever. and replace.
Release mechanism did not Adjust cable tension so release

disengage allowing seat to will pull locking pin mechanism
move from last set position. from last engaged position.
Lubricate release mechanism,
if unserviceable, remove and
replace.
Binding of cable mechanism. Replace cable.
Obstruction or deformation Eliminate obstruction, if
on seat adjustment rail unserviceable, remove and
mechanism. replace rail mechanism.
Restraint system does not Malfunction of locking Replace restraint system. 251000
lock or release properly. mechanism.
Wear, cut or deterioration in a Puncture damage or Remove and replace 251000

questionable section of seat excessive wear. component.
fabric or cushion.

25-10-00 Original

1. Crew Seat Assembly 3. Restraint System
A. Crew Seat Assembly Removal A. Restraint System (Harness) Removal

(1). Remove crew seat assembly (4).
NOTE: Removal of left and right crew seat as
semblies and components are typical. (2). Remove back rest (40) and pan seat
(41) cushions (Ref. Section 25-10-00).
(1). Remove bolts (5) and washers (6)
attaching seat adjustment rails (2) to (3). Remove nut (7), washers (8, 14 and 16),
cockpit floor. bushing (15) and bolt (9) attaching lap
harness (10) to seat back assembly (42).
(2). Carefully lift entire crew seat assembly (4). Remove nut (7), washers (8, 14 and 16),
(4) and remove from aircraft. bushing (15) and screw (17) attaching
B. Crew Seat Assembly Installation crotch harness (10) to seat pan assem
bly (39).
(Ref. Figure 401) (5). Remove and discard nuts (20). Remove
NOTE: Installation of left and right crew seat washers (19) and bolts (18) attaching
assemblies and components are typical. inertia reel (11) and shoulder harness
(10) to seat back (42).
(1). Align crew seat assembly (4) with
(6). Remove and discard nuts (20). Remove
mounting holes in cockpit floor.
washers (33) and screws (37) attaching
(2). Install bolts (5) and washers (6) harness locking handle assembly (38) to
attaching seat adjustment rails (2) to seat pan (39).
cockpit floor. B. Restraint System (Harness) Installation
(3). Torque bolts. (Ref. Figure 401)
2. Seat Cushions, Back Rest and Pan (1). Install bolts (18), washers (19) and new
nuts (20) attaching inertia reel (11) and
A. Seat Cushion Removal shoulder harness (10) to seat back
assembly (42).
(Ref. Figure 401)
(2). Install screws (37), washers (33) and
(1). Pull seat pan cushion (41) up from seat new nuts (20) attaching harness locking
pan assembly (39) hook tape fasteners handle assembly (38) to seat pan
to remove. assembly (39).
(2). Untie lacing of back rest cushion (40) (3). Install screw (17), bushing (15),
from rear of seat back assembly (42) to washers (8, 14 and 16) and nut (7)
remove. attaching crotch harness (10) to seat
pan assembly (39).
B. Seat Cushion Installation
(4). Install bolt (9), bushing (15), washers
(Ref. Figure 401) (8, 14 and 16) and nut (7) attaching lap
harness (10) to seat back (42).
(1). Wrap flaps of back rest cushion (40)
around seat back assembly (42) frame (5). Torque nuts.
and re-tie lacing to secure. (6). Install back rest (40) and pan seat (41)
cushions (Ref. Section 25-10-00).
(2). Push seat pan cushion (41) down
against hook tape fasteners of seat pan (7). Install crew seat assembly (4) in
assembly (39) to secure. aircraft.
Page 401
25-10-00 Original
4. Adjustment Rail Assembly, Crew Seat (4). Remove nuts (20), washers (19) and
bolts (18) attaching inertia reel (11) and
A. Adjustment Rail Assembly Removal shoulder harness (10) to seat back
assembly (42).
(Ref. Figure 401)
(5). Remove seat pan assembly (39) (Ref.
(1). Remove crew seat assembly (4). Section 25-10-00).
(2). Remove forward rail stops (1) with pull (6). Remove nuts (7), washers (8 and 14),
up cables (12) attached. bushings (15) and screws (17) attaching
side tubes (25) to seat back assembly
(3). Remove aft rail stops (13). (42).
(4). Disengage lock system assembly (47) (7). Remove nuts (7), washers (8 and 29)
from adjustment rail assemblies (2) by and bolts (30) attaching diagonal
moving adjustment lever (3) under supports (44) to fixed fitting assemblies
front of seat pan assembly (39). (32).
(5). Slide adjustment rail (2) aft and down

NOTE: When removing bolts (34), tension
springs (55) will fall down inside of upright
to remove from crew seat assembly (4).
support assembly (43).
B. Adjustment Rail Assembly Installation (8). Remove nuts (20), washers (33) and
bolts (34) attaching fitting assemblies
(Ref. Figure 401) (32) to upright support assembly (43).
(1). Retract lock system assembly (47) by (9). Slide seat back assembly (42), fitting
moving adjustment lever (3) under assemblies (32) and attenuation tube
front of seat pan assembly (39). assemblies (54) up and off of support
assembly (43).
(2). While holding adjustment lever (3),
slide adjustment rail assembly (2) B. Seat Back Assembly Installation
forward and up into crew seat assembly
(4). (Ref. Figure 401)
(1). Slide seat back assembly (42), fitting
(3). Lock seat assembly (4) in the most assemblies (32) and attenuation tube
forward position on adjustment rail (2). assemblies (54) down onto upright
(4). Install forward rail stops (1) with pull
up cables (12) attached. NOTE: Tension springs (55) and pull up cables
(12) will have to be lowered down inside of
(5). Install aft rail stops (13). upright support assembly (43) to line up
with fixed fitting assemblies (32) before
(6). Install crew seat assembly (4) in installing bolts (34).
aircraft.
(2). Align loop of tension springs (55) with
5. Seat Back Assembly fitting assemblies (32) and install bolts
(34), washers (33) and nuts (20)
A. Seat Back Assembly Removal attaching fitting assemblies (32) to
(Ref. Figure 401)
(3). Install bolts (30), washers (8 and 29)
(1). Remove crew seat assembly (4). and nuts (7) attaching diagonal
supports (44) to fitting assemblies (32).
(2). Remove back rest cushion (40) (Ref.
Section 25-10-00). (4). Install screws (17), bushings (15),
washers (8 and 14) and nuts (7)
(3). Remove adjustment rail assemblies (2) attaching side tubes (25) to seat back
(Ref. Section 25-10-00). assembly (42).
Page 402
Original 25-10-00
(5). Install seat pan assembly (39) (Ref. (3). Install screws (37), washers (33) and
Section 25-10-00). nuts (20) attaching harness locking
handle assembly (38) to seat pan
(6). Install bolts (18), washers (19) and nuts assembly (39).
(20) attaching inertia reel (11) and
shoulder harness (10) to seat back (42). (4). Install screws (36), washers (33) and
nuts (20) attaching lock system assem
(7). Install adjustment rail assemblies (2) bly (47) to seat pan (39).
(Ref. Section 25-10-00). (5). Install seat pan (41) cushion (Ref.
(8). Install back rest cushion (40) (Ref. Section 25-10-00).
Section 25-10-00). (6). Install crew seat assembly (4) in
aircraft.
(9). Install crew seat assembly (4) in
aircraft. 7. Upright Support Assembly
A. Upright Support Assembly Removal
6. Seat Pan Assembly
(Ref. Figure 401)
A. Seat Pan Assembly Removal (1). Remove crew seat assembly (4).
(Ref. Figure 401) (2). Remove seat back assembly (42) (Ref.
Section 25-10-00).
(3). Remove and discard cotter pin (26).
(2). Remove seat pan (41) cushion (Ref. Remove nut (27), washers (8 and 51)
Section 25-10-00). and bolt (31) attaching upright support
assembly (43), tie tube assembly (50)
(3). Remove nuts (7), washers (8 and 14), and forward roller assembly (49) to
bushings (24) and screws (17) attaching forward rail holder (46).
side tubes (25) to seat pan assembly
(39). B. Upright Support Assembly Installation
(Ref. Figure 401)
(4). Remove nuts (20), washers (33) and
screws (37) attaching harness locking (1). Install bolt (31), washers (8 and 51) and
handle assembly (38) to seat pan (39). nut (27) attaching upright support
assembly (43), tie tube assembly (50)
(5). Remove nuts (20), washers (33) and and forward roller assembly (49) to
screws (36) attaching lock system forward rail holder (46). Install new
assembly (47) to seat pan (39). cotter pin (26).
(6). Remove nuts (7), washers (8 and 22), (2). Install seat back assembly (42) (Ref.
bushings (23) and bolts (21) attaching Section 25-10-00).
seat pan (39) to seat back assembly (3). Install crew seat assembly (4) in
(42). aircraft.
(7). Remove seat pan (39). 8. Cable Roller
B. Seat Pan Assembly Installation A. Cable Roller Removal
(Ref. Figure 401)
(Ref. Figure 401)
(1). Install bolts (21), bushings (23), (2). Remove forward rail stop (1) with pull
washers (8 and 22) and nuts (7) up cable (12) attached.
attaching seat pan assembly (39) to
seat back assembly (42). (3). Remove and discard cotter pin (26).
Remove nut (27), washers (8 and 51)
(2). Install screws (17), bushings (24), and bolt (31) attaching upright support
washers (8 and 14) and nuts (7) assembly (43), tie tube assembly (50)
attaching side tubes (25) to seat pan and forward roller assembly (49) to
(39). forward rail holder (46).
Page 403
25-10-00 Original
(4). Remove and discard cotter pin (52). (2). Install aft rail holder assembly (45)
Remove washer (33) and straight pin (Ref. Section 25-10-00).
(53) that hold cable roller (35) in (3). Install screws (36), washers (33) and
support assembly (43). new nuts (20) attaching lock system
(5). Remove roller (35). assembly (47) to seat pan assembly
(39).
B. Cable Roller Installation (4). Install crew seat assembly (4) in
aircraft.
(Ref. Figure 401)
10. Diagonal Support
(1). Install cable roller (35) in upright
support assembly (43) with straight pin A. Diagonal Support Removal
(53), washer (33) and new cotter pin (Ref. Figure 401)
(52).
(2). Route pull up cable (12) through rollers (2). Remove and discard cotter pin (26).
(35) and forward roller assembly (49). Remove nut (27), washers (8 and 29)
and bolt (28) attaching lower end of
(3). Install bolt (31), washers (8 and 51) and diagonal support (44), tie tube assem
nut (27) attaching upright support bly (50) and aft roller assembly (48) to
assembly (43), tie tube assembly (50) aft rail holder assembly (45).
and forward roller assembly (49) to
forward rail holder (46). Install new (3). Remove nut (7), washers (8 and 29) and
cotter pin (26). bolt (30) attaching upper end of
diagonal support (44) to fixed fitting
(4). Install forward rail stop (1) with pull up assembly (32).
cable (12) attached. (4). Remove support (44).
(5). Install crew seat assembly (4) in B. Diagonal Support Installation
aircraft.
(Ref. Figure 401)
9. Lock System Assembly (1). Install bolt (30), washers (8 and 29) and
nut (7) attaching upper end of diagonal
A. Lock System Assembly Removal support (44) to fixed fitting assembly
(32).
(Ref. Figure 401)
(2). Install bolt (28), washers (8 and 29) and
(1). Remove crew seat assembly (4). nut (27) attaching lower end of diagonal
support (44), tie tube assembly (50) and
(2). Remove and discard nuts (20). Remove aft roller assembly (48) to aft rail
washers (33) and screws (36) attaching holder assembly (45). Install new cotter
lock system assembly (47) to seat pan pin (26).
assembly (39).
(3). Remove aft rail holder assembly (45) aircraft.
(Ref. Section 25-10-00). 11. Aft Rail Holder Assembly
(4). Remove and discard nuts (20). Remove A. Aft Rail Holder Assembly Removal
washers (33) and bolts (18) attaching
(Ref. Figure 401)
lock system (47) to aft rail holder (45).
B. Lock System Assembly Installation
(Ref. Figure 401) Remove nut (27), washers (8 and 29)
and bolt (28) attaching lower end of
(1). Install bolts (18), washers (33) and new diagonal support (44), tie tube assem
nuts (20) attaching lock system assem bly (50) and aft roller assembly (48) to
bly (47) to aft rail holder assembly (45). aft rail holder assembly (45).
Page 404
Original 25-10-00
(3). Disengage lock system assembly (47) B. Forward Rail Holder Installation
from seat adjustment rails (2) by
moving adjustment lever (3) under (Ref. Figure 401)
front of seat pan assembly (39).
(1). Align forward roller assembly (49) in
(4). Remove rail holder assembly (45). upright support assembly (43) and
route pull up cable (12) around roller
assembly (49).
bolts (18) attaching lock system (47) to (2). Install bolt (31), washers (8 and 51) and
aft rail holder (45). nut (27) attaching support assembly
(43), tie tube assembly (50) and forward
B. Aft Rail Holder Assembly Installation roller assembly (49) to forward rail
holder (46). Install new cotter pin (26).
(Ref. Figure 401)
(3). Install forward rail stop (1) with pull up
(1). Install bolts (18), washers (33) and nuts cable (12) attached.
(20) attaching lock system assembly
(47) to aft rail holder assembly (45). (4). Install crew seat assembly (4) in
aircraft.
(2). Retract lock system (47) by moving
adjustment lever (3) under front of seat 13. Forward Roller Assembly
pan assembly (39).
A. Forward Roller Assembly Removal
(3). Slide aft rail holder assembly (45) onto (Ref. Figure 401)
adjustment rail assembly (2).
nut (27) attaching lower end of diagonal (2). Remove forward rail stop (1) with pull
support (44), tie tube assembly (50) and up cable (12) attached.
aft roller assembly (48) to aft rail
holder (45). Install new cotter pin (26). (3). Remove and discard cotter pin (26).
(5). Install crew seat assembly (4) in and bolt (31) attaching upright support
aircraft. assembly (43), tie tube assembly (50)
and forward roller assembly (49) to
forward rail holder (46).
12. Forward Rail Holder
(4). Remove forward roller (49).
A. Forward Rail Holder Removal
B. Forward Roller Assembly Installation
(Ref. Figure 401)
(Ref. Figure 401)
(1). Align forward roller assembly (49) in
upright support assembly (43) and
(2). Remove forward rail stop (1) with pull
route pull up cable (12) around roller
up cable (12) attached.
assembly (49).
(3). Remove and discard cotter pin (26). (2). Install bolt (31), washers (8 and 51) and
Remove nut (27), washers (8 and 51) nut (27) attaching support assembly
and bolt (31) attaching upright support (43), tie tube assembly (50) and forward
assembly (43), tie tube assembly (50) roller assembly (49) to forward rail
and forward roller assembly (49) to holder (46). Install new cotter pin (26).
(3). Install forward rail stop (1) with pull up
(4). Remove forward rail holder (46). cable (12) attached.
Page 405
25-10-00 Original
(4). Install crew seat assembly (4) in B. Side Tube Installation

aircraft.
(Ref. Figure 401)
14. Aft Roller Assembly (1). Install screws (17), bushings (15),
washers (8 and 14) and nuts (7)
A. Aft Roller Assembly Removal attaching side tubes (25) to seat back
assembly (42).
(Ref. Figure 401)
(2). Install screws (17), bushings (24),
(1). Remove crew seat assembly (4). washers (8 and 14) and nuts (7)
attaching side tubes (25) to seat pan
(2). Remove and discard cotter pin (26). assembly (39).
and bolt (28) attaching lower end of (3). Install back rest (40) and pan seat (41)
cushions (Ref. Section 25-10-00).
diagonal support (44), tie tube assem
bly (50) and aft roller assembly (48) to (4). Install crew seat assembly (4) in
aft rail holder assembly (45). aircraft.
(3). Remove aft roller (48). 16. Tie Tube Assembly
A. Tie Tube Assembly Removal
B. Aft Roller Assembly Installation
(Ref. Figure 401)
(Ref. Figure 401)
(1). Align aft roller assembly (48) in (2). Remove and discard cotter pin (26).
diagonal support (44) and aft rail Remove nut (27), washers (8 and 29)
holder (45). and bolt (28) attaching lower end of
diagonal support (44), tie tube assem
bly (50) and aft roller assembly (48) to
nut (27) attaching lower end of diagonal
aft rail holder assembly (45).
support (44), tie tube assembly (50) and
aft roller assembly (48) to aft rail (3). Remove and discard cotter pin (26).
holder (45). Install new cotter pin (26). Remove nut (27), washers (8 and 51)
and bolt (31) attaching upright support
(3). Install crew seat assembly (4) in assembly (43), tie tube assembly (50)
aircraft. and forward roller assembly (49) to
15. Side Tube
(4). Remove tie tube (50).
(Ref. Figure 401) B. Tie Tube Assembly Installation
A. Side Tube Removal (Ref. Figure 401)
(1). Align tie tube assembly (50) with lower
end of diagonal support (44) and
(2). Remove back rest (40) and pan seat upright support assembly (43).
(41) cushions (Ref. Section 25-10-00). (2). Install bolt (28), washers (8 and 29) and
nut (27) attaching lower end of diagonal
(3). Remove nuts (7), washers (8 and 14), support (44), tie tube assembly (50) and
bushings (24) and screws (17) attaching aft roller assembly (48) to aft rail
side tubes (25) to seat pan assembly holder assembly (45).
(39).
(4). Remove nuts (7), washers (8 and 14), nut (27) attaching upright support
bushings (15) and screws (17) attaching assembly (43), tie tube assembly (50)
side tubes (25) to seat back assembly and forward roller assembly (49) to
(42). forward rail holder (46).
Page 406
Original 25-10-00
(4). Install new cotter pins (26). (5). Slide attenuation tube (54) up and out
of fixed fitting assembly (32).
aircraft. NOTE: When removing bolts (34), tension
springs (55) will fall down inside of upright
17. Attenuation Tube support assemblies (43).
A. Attenuation Tube Removal (6). Remove nuts (20), washers (33) and
bolts (34) attaching fitting assemblies
(Ref. Figure 401) (32) to upright support assemblies (43).
(1). Remove crew seat assembly (4). (7). Slide seat back assembly (42) and
fitting assemblies (32) up and off of
(2). Remove nut (7), washer (8) and bolt support assembly (43).
(56) that attaches attenuation tube (54)
to seat back assembly (42). (8). Remove fitting assembly (32).
(3). Slide attenuation tube (54) up and out B. Fixed Fitting Assembly Installation
of fixed fitting assembly (32). (Ref. Figure 401)
B. Attenuation Tube Installation (1). Slide seat back assembly (42) and fixed
fitting assemblies (32) down onto
(Ref. Figure 401) upright support assembly (43).
(1). Slide attenuation tube (54) down and NOTE: Tension springs (55) and pull up cables
into fixed fitting assembly (32). (12) will have to be lowered down inside of
upright support assembly (43) to line up
(2). Install bolt (56), washer (8) and nut (7)
with fixed fitting assemblies (32) before
attaching attenuation tube (54) to seat
installing bolts (34).
back assembly (42).
(2). Align loop of tension springs (55) with
(3). Install crew seat assembly (4). fitting assemblies (32) and install bolts
(34), washers (33) and nuts (20)
18. Fixed Fitting Assembly attaching fitting assemblies (32) to
A. Fixed Fitting Assembly Removal support assembly (43).
(3). Slide attenuation tubes (54) down and
(Ref. Figure 401)
into fixed fitting assemblies (32).
(1). Remove crew seat assembly (4). (4). Install bolts (56), washers (8) and nuts
(2). Remove forward rail stops (1). (7) attaching attenuation tubes (54) to
seat back assembly (42).
(3). Remove nuts (7), washers (8 and 29) (5). Install bolts (30), washers (8 and 29)
and bolts (30) attaching upper end of and nuts (7) attaching upper end of
diagonal supports (44) to fixed fitting
diagonal supports (44) to fixed fitting
assemblies (32).
assemblies (32).
(4). Remove nuts (7), washers (8) and bolts (6). Install forward rail stops (1).
(56) that attach attenuation tubes (54)
to seat back assembly (42). (7). Install crew seat assembly (4).
Page 407
25-10-00 Original
10
42
40
7
8
14
15
20 (4 17
PL)
20 19 (4 41
33 PL)
55 34 1811(4
PL)
4 7
25 8
54 7 29
8 30
14 44
12 REF 16
15
17 43
32 7
8 39
56
7 7 7
8 43 8 8
3 22 14 14
23 24 16
20 (2 PL) 21 44 REF 17
33 (2 PL) VIEW LOOKING 2 48 15
36 (2 PL OUTBOARD 9
50 26
47
52 27
35 8
20 (2 PL) 53 13
54 29
33 (4 PL)
12 28
37 (2 PL
38
1 45
5 (6 PL)
6 (6 PL)
26
2 46 27
49 8
51
31
20 20
33 47 33
18 18
9G25007A
Figure 401. Crew Seat Assembly
Page 408
Original 25-10-00

1. FORWARD RAIL STOP 29. WASHER
2. ADJUSTMENT RAIL ASSEMBLY 30. BOLT
3. ADJUSTMENT LEVER 31. BOLT
4. CREW SEAT ASSEMBLY 32. FIXED FITTING ASSEMBLY
5. BOLT 33. WASHER
6. WASHER 34. BOLT
7. NUT 35. CABLE ROLLER
8. WASHER 36. SCREW
9. BOLT 37. SCREW
10. RESTRAINT HARNESS 38. HARNESS LOCKING HANDLE ASSEMBLY
11. INERTIA REEL 39. SEAT PAN ASSEMBLY
12. PULL UP CABLE 40. BACK REST CUSHION
13. AFT RAIL STOP 41. SEAT PAN CUSHION
14. WASHER 42. SEAT BACK ASSEMBLY
15. BUSHING 43. UPRIGHT SUPPORT ASSEMBLY
16. WASHER 44. DIAGONAL SUPPORT
17. SCREW 45. AFT RAIL HOLDER ASSEMBLY
18. BOLT 46. FORWARD RAIL HOLDER
19. WASHER 47. LOCK SYSTEM ASSEMBLY
20. NUT 48. AFT ROLLER ASSEMBLY
21. BOLT 49. FORWARD ROLLER ASSEMBLY
22. WASHER 50. TIE TUBE ASSEMBLY
23. BUSHING 51. WASHER
24. BUSHING 52. COTTER PIN
25. SIDE TUBE 53. STRAIGHT PIN
26. COTTER PIN 54. ATTENUATION TUBE ASSEMBLY
27. NUT 55. TENSION SPRING
28. BOLT 56. BOLT
19. General (Soft) Insulation Panel Removal 20. Coat Hook

Some components in this section require A. Coat Hook Removal
removal of soft interior insulation panels in
order to gain access to the components (Ref. Figure 402)
attaching hardware. The following procedure
(1). Remove attaching hardware that
explains the basic task of their removal and
secures coat hook (3) to mounting
installation.
support.
NOTE: Most soft insulation panels are held
only with hook tape fasteners. Others may (2). Remove coat hook (3).
be held with hook tape and captive fasten B. Coat Hook Installation
ers.
(Ref. Figure 402)
A. Insulation Panel Removal
(1). Position coat hook (3) with mounting
(1). Disengage captive fasteners that secure support.
insulation panel, if applicable.
(2). Install attaching hardware.
(2). Carefully separate hook tape fasteners
by pulling panel away from mounting 21. Area Light
surface.
A. Area Light Removal
B. Insulation Panel Installation
(Ref. Figure 402)
(1). Align insulation panel and hook tape
fasteners with mating surface hook (1). Remove screws (1, 2).
tape attachments. Press surfaces
together to secure. (2). Disconnect electrical connection.
(2). Engage captive fasteners, if applicable. (3). Remove area light (4).
Page 409
25-10-00 Original
B. Area Light Installation (2). Remove trapping strip (9).

(Ref. Figure 402) B. Carpet Trapping Strip Installation
(1). Connect electrical connection. (Ref. Figure 402)

(1). Align carpet trapping strip (9) with
(2). Install screws (1, 2) attaching area
holes in floor.
light (4).
(2). Install screws (7) and washers (8)
22. Cockpit Utility Light attaching trapping strip (9).
A. Cockpit Utility Light Removal 25. Carpet Cockpit Floor
(Ref. Figure 402) A. Carpet Removal
(1). Remove attaching hardware from (Ref. Figure 402)
support. (1). Loosen heel rest assemblies (Ref
(2). Disconnect electrical connection. Section 67-20-00).
(2). Remove screws (7) and washers (8) that
(3). Remove utility light (5).
attach carpet trapping strip (9) to floor.
B. Cockpit Utility Light Installation (3). Remove cyclic stick boot (Ref. Section
(Ref. Figure 402) 67-10-00).
(4). Pull carpet (10) back and up from hook
(1). Connect electrical connection.
tape attachments and raise over cyclic
(2). Install attaching hardware securing stick.
utility light (5) to support. B. Carpet Installation
23. Controls Closet Panel, Inboard (Ref. Figure 402)
A. Controls Closet Panel, Inboard Removal (1). Pass carpet (10) over cyclic stick and
lay down over hook tape attachments
(Ref. Figure 402) while sliding front end under heel rests.
(1). Disengage captive fasteners that secure (2). Install screws (7) and washers (8)
insulation panel to frame. attaching carpet trapping strip (9) to
floor.
(2). Remove inboard controls closet panel
(6). (3). Install cyclic stick boot (Ref. Section
67-10-00).
B. Controls Closet Panel, Inboard
Installation (4). Tighten down heel rest assemblies (Ref.
Section 67-20-00).
(Ref. Figure 402)
26. Lower Panel, Left Hand
(1). Align inboard controls closet panel (6) A. Lower Panel, Left Hand Removal
and engage fasteners.
(Ref. Figure 402)
(2). Engage captive fasteners securing
insulation panel to frame. (1). Disengage captive fasteners that secure
LH lower panel (11) to frame.
24. Carpet Trapping Strip
(2). Remove panel (11).
A. Carpet Trapping Strip Removal B. Lower Panel, Left Hand Installation
(1). Remove screws (7) and washers (8) that (1). Engage captive fasteners attaching LH
attach carpet trapping strip (9) to floor. lower panel (11) to frame.
Page 410
Original 25-10-00
27. Top Panel Assembly Left Hand (2). Press panel (15) surface against hook
tape fasteners to attach.
A. Top Panel Removal
30. Main Covers, Center Beam, LH and RH
(Ref. Figure 402)
A. Main Covers, Center Beam Removal
(1). Disengage captive fasteners that attach
LH top panel (12) to frame. (Ref. Figure 402)
(2). Remove panel (12). (1). Disengage captive fasteners that attach
center beam main covers (14) to frame.
B. Top Panel Installation
(2). Remove main covers (14).
(Ref. Figure 402)
B. Main Covers, Center Beam Installation
(1). Align LH top panel (12) with frame (Ref. Figure 402)
holes.
(1). Align center beam main covers (14)
(2). Engage captive fasteners attaching with frame holes.
panel (12) to frame.
(2). Engage captive fasteners attaching
28. Lower Panel, Right Hand main covers (14).
A. Lower Panel, Right Hand Removal 31. Forward Cover, Center Beam
(Ref. Figure 402) A. Forward Cover, Center Beam Removal
(1). Disengage captive fasteners that attach (Ref. Figure 402)
RH lower panel (13) to frame.
(2). Remove lower panel (13). that attach center beam forward cover
(17) to center beam.
B. Lower Panel, Right Hand Installation
(2). Remove cover (17).
(Ref. Figure 402)
B. Forward Cover, Center Beam Installation
(1). Align RH lower panel (13) with frame
(Ref. Figure 402)
holes.
(1). Align center beam forward cover (17)
(2). Engage captive fasteners attaching with mounting holes in center beam.
panel (13) to frame.
29. Side Panel attaching forward cover (17).
A. Side Panel Removal 32. Top Panel Assembly Right Hand
(Ref. Figure 402) A. Top Panel Removal
NOTE: Left and right side panels are typical. (Ref. Figure 402)
(1). Separate hook tape fasteners by pulling (1). Disengage captive fasteners that attach
side panel (15) away from mounting RH top panel (18) to frame.
surface. (2). Remove panel (18).
(2). Remove panel (15). B. Top Panel Installation
B. Side Panel Installation (Ref. Figure 402)
(Ref. Figure 402) (1). Align RH top panel (18) with frame
mounting holes.
(1). Align side panel (15) and hook tape
fasteners with mating surface hook (2). Engage captive fasteners attaching
tape attachments. panel (18).
Page 411
25-10-00 Original
33. Roof Panel (2). Remove screws (26 and 27) that attach
interior door handle (25) and remove
A. Roof Panel Removal handle.
(Ref. Figure 402) (3). Remove decorative caps (28), screws

(29) and washers (30) that attach door
NOTE: Left and right side panels are typical. panel (24) to door assembly.
(1). Carefully separate hook tape fasteners (4). Remove panel (24).
that attach roof panel (19) to airframe.
B. Door Panel Installation
(2). Remove panel (19).
(Ref. Figure 402)
B. Roof Panel Installation
(1). Align door panel (24) with cockpit door
(Ref. Figure 402) assembly and install washers (30),
screws (29) and decorative caps (28).
(1). Align hook tape fasteners on roof panel
(2). Install interior door handle (25) and
(19) with mating frame fasteners.
attach with screws (26 and 27).
(2). Press panel (19) surface against hook (3). Install cockpit door assembly (Ref.
tape fasteners to attach. Section 52-00-00).
34. InFill Panel 36. Support, Headset Jack
A. InFill Panel Removal A. Support, Headset Jack Removal
(1). Remove screws (16) and washers (8) (1). Remove LH center beam main cover
that attach in-fill panel (23) to frame. (14), Ref. Section 25-10-00).
(2). Remove panel (23). (2). Remove screws (20) and washers (21)
that attach headset jack support (22) to
B. InFill Panel Installation center beam.
(Ref. Figure 402) (3). Disconnect connector and jack recep

tacles from support (22).
(1). Align in-fill panel (23) with holes in
frame. (4). Remove support installation (22).
(2). Install screws (16) and washers (8) B. Support, Headset Jack Installation
attaching panel (23).
(Ref. Figure 402)
35. Door Panel, Cockpit (1). Attach connector and jack receptacles
to headset jack support (22).
A. Door Panel Removal
(2). Align support (22) with mounting holes
(Ref. Figure 402) in center beam.
NOTE: Left and right side door panels are typi (3). Install screws (20) and washers (21)
cal. attaching support (22) to center beam.
(1). Remove cockpit door assembly (Ref. (4). Install LH center beam main cover (14)
Section 52-00-00). (Ref. Section 25-10-00).
Page 412
Original 25-10-00
22 20
21 2
5 14
(EACH SIDE) 12 1
19
23
18
19
8
(12 PL) 12 (REF)
16 3
(12 PL) 14
(EACH SIDE)
24 15
6
26
17 27 11
28 13
(7 PL) 29
30 25
10
7 (7 PL)
8
9G25008A
Figure 402. Crew Compartment Interior Trim
Page 413
25-10-00 Original

1. SCREW 16. SCREW
2. SCREW 17. CENTER BEAM FORWARD COVER
3. COAT HOOK 18. RH TOP PANEL ASSEMBLY
4. AREA LIGHT 19. ROOF PANEL
5. UTILITY LIGHT 20. SCREW
6. CONTROLS CLOSET PANEL, INBOARD 21. WASHER
7. SCREW 22. HEAD SET JACK SUPPORT
8. WASHER 23. INFILL PANEL
9. CARPET TRAPPING STRIP 24. DOOR PANEL
10. CARPET 25. DOOR HANDLE, INTERIOR
11. LH LOWER PANEL 26. SCREW
12. LH TOP PANEL ASSEMBLY 27. SCREW
13. RH LOWER PANEL 28. DECORATIVE CAP
14. CENTER BEAM MAIN COVER 29. SCREW
15. SIDE PANEL 30. WASHER
Page 414
Original 25-10-00
CREW COMPARTMENT
INSPECTION/TEST
1. Crew Compartment Adhesive Paste, Acrylic (C422)
A. Seat Inspection (Area 1)
Consumable Materials (b). Make sure hook tape fasteners on

(Ref. CSPSPM) seat pan are correctly attached. If
Item Nomenclature loose, bond with adhesive paste
(C422).
C422 Adhesive Paste, Acrylic
(c). Make sure loop tape fasteners on
cushions are correctly attached.
(1). Examine crew seats for correct installa (5). Examine attenuation tubes for condi
tion. If necessary, tighten attach tion as follows:
hardware. If play is more than 0.020
in. (0.508 mm), replace attach hard (a). Deformation and cracks. None
ware. permitted.
(b). Scratches through external coating
(2). Examine seat adjust mechanism for or paint. None permitted.
correct installation and operation as
follows: (c). Plastic cap at upper energy absorber
attach point for damage. Damage to
(a). Make sure handle fully operates cap can be an indication energy
position lock pin mechanism. absorber is misaligned or damaged.
Energy absorber must be aligned
with seat support structure (along
(b). Make sure position lock pin fully tube center line). No damage per
engages selected rail position. mitted.
Maximum radial play when engaged,
0.010 in. (0.254 mm). NOTE: It is not necessary to do maintenance on
or lubricate the attenuation tubes.
(c). Examine cables and rails for condi (6). Remove corrosion. Maximum depth
tion and correctly installation. permitted, 0.010 in (0.254 mm) (Ref.
CSP-SPM).
(3). Make sure seat cushions are clean. B. Seat Energy Absorption System (EAS)
Inspection
(4). Examine seat cushions for tears, cuts,
or other damage. (Ref. Figure 601)
(1). Measure the clearance between the
(a). The maximum permitted separation fixed fitting and spacer on the main
at fabric seams, 1.5 in. (38.1 mm) tube on the two sides of each crew seat.
(across seam) and a width of 2 in. Maximum clearance permitted, 0.1 in.
(50.8 mm) (along seam). (2.54 mm)
Page 601
MAIN
TUBE
SEAT
FRAME
FIXED FITTING
0.1 IN
(2.54 mm)
CREW
SEAT
SPACER
25
9G25025
Figure 601. Seat EAS Inspection

C. Seat Restraint System Inspection 2). With tension released, harness
(Area 1) strap must automatically retract
back into reel mechanism.
(1). Examine restraint system for correct
installation and operation as follows: 3). Apply a sudden forward pull on
seat belt or shoulder strap to make
(a). Belt adjust mechanism for correct sure inertia reel locks.
operation and condition. No damage
permitted. 4). Examine handle and cable of
(b). Area of belt that goes through adjust manual lock system for condition
mechanism for wear. No damage to and correct operation. No defects
belt permitted. permitted.
(c). Inertia reel for damage, wear, and (d). Belts for cuts, nicks, tears, or other
smooth operation as follows: damage. No damage permitted.
1). Make sure harness strap can not (e). Do a check for correct operation of
be pulled out of inertia reel when buckles, latch and release. No defects
fully extended. permitted.
Page 602
D. Trim Inspection (Area 1) NOTE: Repairs are not recommended when the
center of the damage is less than 1.97 in.
(50 mm) from a fastener or 3.15 in. (80
(Ref. CSPSPM)
mm) from edge of panel.
Item Nomenclature (b). Repair holes or impact damage on
C714 Tape, Adhesive, Clear composite honeycomb panels. Maxi
C422 Adhesive Paste, Acrylic mum repair dimension, 1.57 in. (40
C812 Filler Compound mm).
(7). Make sure you can read the placards

(1). Examine soft insulation panels for and decals.
condition and wear.
(8). Make sure placards and decals are
(a). Make sure panels are clean and have correctly installed.
no stains, tears, or corrosion on metal
components. For procedures to clean (9). Examine checklist and magnetic
(Ref. CSP-SPM). compass card for condition.
NOTE: Repair minor damage to panels, use (10). Make sure you can read checklist and
clear adhesive tape (C714). magnetic compass card.
Adhesive Paste, Acrylic (C422) E. Seat Operational Test
(1). Operate seat adjust lever under front of
crew seat.
(2). Examine panels and fuselage structure (2). Make sure position lock pin mechanism
for missing or loose hook and loop tape releases.
fasteners. If loose, bond with adhesive
paste (C422). (3). Hold lock mechanism unlocked and
move seat forward-up and aft-down.
(3). Make sure interior lights are service Make sure seat moves smoothly
able and electrical connections have no through full travel.
damage. No damage permitted.
(4). Move seat forward-up and aft-down
(4). Examine carpet for cuts, tears, correct and release lock mechanism at each
installation, or other unserviceable lock position. Make sure seat locks in
conditions. all positions and lock pins fully engage.
(5). Examine composite or laminated panels F. Seat Restraint System Operational Test
for correct installation and condition.
(1). Latch lap belt and shoulder harness.
(6). Examine panels for dents, scratches,
Make sure latch mechanism operates
and impact damage.
correctly. Make sure straps do not
NOTE: Repairs are not recommended for disengage from buckle unless released
scratches or dents which are less than 1.2 by buckle operation.
in. (30.5 mm) from a fastener or 1.97 in.
(50 mm) from edge of panel. (2). Move manual control handle forward to
the manual lock position. Make sure
(a). Repair scratches or dents with filler straps lock. Do again at one other
compound (C812). position.
Page 603
Page 604
Section
252000
Cabin Compartment

CABIN COMPARTMENT INTERIOR

1. Equipment / Furnishings General The seats are nonadjustable, with an energy
attenuating structure and three-point
The standard equipment and furnishings
restraint system.
provide seating for the pilot, copilot, and six
passengers. Each crew and cabin seat is
equipped with a restraint system. The basic The cabin seats are located in the cabin
furnishings include interior trim, acoustic compartment. Each cabin seat support tube
insulation, floor coverings, and other miscella assembly attaches to a pair of seat fittings
neous items for furnishing of the helicopter that are attached to the cabin compartment
interior. floor and roof structures.
The business interior furnishings include The energy attenuating structure is attached
additional soundproofing and upgraded trim to the seat support tube assembly. The seat
panels for the walls and roof. back and seat bottom assembly is covered with
2. Cabin Compartment Equipment / fabric. The seat back angle is fixed for each
Furnishings cabin seat at 15 degrees, the seat bottom angle
is fixed at 20 degrees. Each seat bottom folds
(Ref. Figure 1, Figure 2 and Figure 3) up for accommodating cargo without removing
The cabin compartment includes up to six the seat. Each seat back folds forward to aid in
energy attenuating cabin seats with restraint stowing or retrieving baggage.
systems. The cabin compartment can be
configured with up to six individual cabin Incorporated in the seat supports are energy
seats, three forward facing and three aft absorbers that initiate stroking of the seat
facing. The cabin compartment is furnished when severe vertical loads are applied to the
with close-out and insulation panels installed seat assembly. Because of this feature, No
to the walls and roof in the utility version, and stowage under seats is allowed. Each cabin
hard roof panels in the commercial and seat has a minimum available stroking
business versions. The Business cabin interior distance of 6.5 inches.
(902 CONFIG) also introduces an upgraded
wall panel configuration. Wall soundproofing B. Restraint System Cabin Seats
was added with the business interior option to
improve cabin comfort. Trim panels are also The cabin seats are equipped with either the
installed to both entry doors. The floor area is early configuration - three-point restraint
covered with carpet material which extends system, or the current configuration - four-
under the passenger seats. An area light is point system. Both restraints combine a safety
installed in the roof at each entry door position (lap) belt and a single or double strap shoulder
to provide light to the cabin compartment. harness. The lap belt and shoulder straps are
Mounted in the roof panels are passenger fabricated from polyester webbing with sewn
service units (commercial/business interior) in buckles and attach fittings.
providing individually directed vent ducts and
a reading light for each seat position. The C. Tie Downs Cabin Compartment
cabin area can be configured in either a
commercial, business or utility version interior.
The tie downs are located at various locations
The cabin compartment is also equipped with in the cabin compartment flooring. When cabin
a 28 Vdc utility outlet and headset plug-in seats are in the folded up position, cargo can
jack. be stowed on the floor and secured with the tie
A. Cabin Seats down attachments. When occupied, cargo or
baggage may not be stowed under the cabin
(Ref. Figure 1)
seats at any time, as this may inhibit or
The cabin seats are interchangeable, indepen restrict the energy attenuating function of the
dently removed and installed without tools. seat mechanism.
Page 1
25-20-00 Original
ATTENUATION
THREE-POINT TUBES
RESTRAINT SYSTEM
FOUR-POINT
RESTRAINT SYSTEM
9G25018A
Figure 1. Cabin Seat Assemblies
Page 2
Original 25-20-00
PSU AFT
CLOSEOUT PANEL
PSU FWD
LIGHT SUPPORT PLATE
LIGHT SUPPORT UNIT
AREA LIGHT
FWD ROOF PANEL
AFT ROOF PANEL

LIGHT SUPPORT UNIT
THRESHOLD CENTER ROOF PANEL
THRESHOLD
CABIN CARPET
CABIN FLOOR
9G250031B
Figure 2. Cabin Interior/Trim Commercial/Business (Sheet 1 of 2)
Page 3
25-20-00 Original
WINDOW REVEAL
TRAPPING STRIP
PULL HANDLE
DOOR PANEL
AFT BULKHEAD
SIDEWALL PANEL PANEL
SIDEWALL PANEL
BAGGAGE
CLOSEOUT
PANEL
FWD BULKHEAD PANEL
9G250032A
Figure 2. Cabin Interior/Trim Commercial/Business (Sheet 2 of 2)
Page 4
Original 25-20-00
CLOSEOUT
PANELS
ROOF PANELS
CLOSEOUT VENT GASPER
PANEL
CLOSEOUT
PANELS
THRESHOLD AREA LIGHT
VENT GASPER
THRESHOLD
CARPET
FLOOR
STRUCTURE HOOK
DOOR STRUCTURE TAPE
TRAPPING STRIP
PULL HANDLE
DOOR TRIM HOOK

TAPE
HOOK
SIDE PANEL TAPE
HOOK
TAPE
HOOK TAPE
SIDE PANEL
AFT BULKHEAD
PANEL
HEAT VENT
FWD BULKHEAD
PANEL 9G25004B
Figure 3. Cabin Interior/Trim Utility
Page 5/(6 blank)

25-20-00 Original

FAULT ISOLATION
1. Interior Assemblies Troubleshooting Troubleshooting tables should be used with the
brief summary of seat assemblies faults, which detailed procedures referred to in this and
may be encountered (Ref. Table 101). other chapters of the manual.
Cabin seat does not close up Hinging mechanism is Isolate problem component, 252000
into stowed position. binding or damaged. remove and replace.
Restraint system does not Malfunction of buckle Replace harness assembly. 252000
lock or release properly. mechanism.
Wear, cut or deterioration in a Puncture damage or Remove and replace 252000

questionable section of seat excessive wear. component.
fabric or cushion.
Loose or unsecured interior Loose hook tape. Remove loose hook tape and 252000
panel. replace.
Loose fastener or Determine loose fastener

provisioning attachment. location and replace.

25-20-00 Original

General - Unless noted, individual interior (1). Install bolts (6), bushings (7), washers
components are common to all trim configura (5, 9 and 10) and nuts (4) attaching lap
tions - Business, Commercial and Utility. restraint harness (13) to seat tubes.
1. Cabin Seat Assembly (2). Install bolts (8), bushings (12), washers
(5 and 11) and nuts (4) attaching
A. Cabin Seat Assembly Removal shoulder restraint harness (13) to seat
tubes.
(Ref. Figure 401)
(3). Torque nuts.
(1). Depress spring loaded collar to disen
gage BROWNLINE fittings (1) on each 3. Cabin Seat Fabric Assembly
end of attenuation tube (2) to release A. Cabin Seat Fabric Removal
cabin seat assembly (2).
(Ref. Figure 402)
(2). Remove seat assembly (2).
(1). Remove cabin seat assembly from
B. Cabin Seat Assembly Installation aircraft.
(Ref. Figure 401) (2). Untie seat fabric cord (3).
(1). Align cabin seat assembly (2) with seat (3). Remove existing seat fabric assembly
anchor plates (3). (1).
B. Cabin Seat Fabric Installation
(2). Depress spring loaded collar to engage
BROWNLINE fittings (1) on each end (Ref. Figure 402)
of cabin seat assembly (2) and insert
into mating roof and floor anchor plates (1). Install cabin seat fabric assembly (1)
(3) to secure. Floor attachments should around seat pan (4) and secure to seat
be secured first, and then ceiling back frame.
fittings. NOTE: Tension seat fabric to seat pan per the
following steps.
(3). Ensure fitting collars have fully and
properly engaged mating base attach (2). Make a bowline knot (2) (Ref. stage 1)
ments. on one of cord (3) ends.
2. Restraint System (3). Thread cord (3) around bottom of seat

pan (4) (Ref. top view).
A. Restraint System Removal
(4). Thread the free end of cord (3) through
(Ref. Figure 401) the bowline (2) (Ref. stage 2) loop and
bring to required tension by applying
(1). Remove nuts (4), washers (5 and 11), 25 kg. (55.13 lbs.) minimum load.
bushings (12) and bolts (8) that attach
(5). Tie knot while keeping tension (Ref.
shoulder restraint harness (13) to seat
stages 3 and 4).
tubes.
(6). Secure knot with tie-down straps (5)
(2). Remove nuts (4), washers (5, 9 and 10), (Ref. stage 5).
lap restraint harness (13) to seat tubes. (7). Apply shrink sleeve (6) on ends of cord
(3) (Ref. stage 5).
B. Restraint System Installation
(8). Install cabin seat assembly into
(Ref. Figure 401) aircraft.
Page 401
25-20-00 Original
13
3
1
2
5 8
12 FOUR-
5 POINT
RESTRAINT
11 1
4 1
HARDWARE PATTERN
TYPICAL 3
9
10 9
13 6
4
7 5
HARDWARE PATTERN
TYPICAL
13
NOTE: EARLY CONFIGURATION IS THREE-POINT RESTRAINT
9G25010C
1. BROWNLINE FITTING 8. BOLT
2. ATTENUATION TUBE/SEAT ASSEMBLY 9. WASHER
3. ANCHOR PLATES 10. WASHER
4. NUT 11. WASHER
5. WASHER 12. BUSHING
6. BOLT 13. RESTRAINT HARNESS
7. BUSHING
Figure 401. Cabin Seats/Restraint System
1. CABIN SEAT FABRIC ASSEMBLY 4. SEAT PAN

2. BOWLINE KNOT 5. TIEDOWN STRAPS
3. CORD 6. SHRINK SLEEVE
Figure 402. Cabin Seat Fabric Installation
Page 402
4. Insulation (Wall) Panels (Commercial and 6. Acoustic Insulation (Roof)

Utility)
A. Acoustic Insulation Removal
NOTE: Most (soft) insulation panels are held
only with hook tape fasteners. Others may (Ref. Figure 403)
be held with hook tape and captive fasten NOTE: Acoustic insulation (23) sections (pil
ers. lows), of various sizes, are individually in
serted into the airframe roof structure cavi
A. Insulation Panel Removal
ties.
(Ref. Figure 403 and Figure 404) (1). Remove forward, aft and center roof
(1). Disengage captive fasteners that attach panels (6) (Ref. Section 25-20-00).
insulation panel (19, Figure 403 or 13, (2). Remove light support units (9) (Ref.
Figure 404), if applicable. Section 25-20-00).
(2). Carefully separate hook tape fasteners (3). Remove aft and forward PSU panels (7)
by pulling panel (19, Figure 403 or 13, (Ref. Section 25-20-00).
Figure 404) away from mounting
surface. (4). Remove individual roof acoustic
insulation (23) sections as required.
B. Insulation Panel Installation
B. Acoustic Insulation Installation
(Ref. Figure 403)
(1). Align insulation panel (19, Figure 403
or 13, Figure 404) and hook tape (1). Install individual roof acoustic insula
fasteners with mating surface hook tion (23) sections as required.
tape attachments. Press surfaces (2). Install aft and forward PSU panels (7)
together to secure. (Ref. Section 25-20-00).
(2). Engage captive fasteners, if applicable. (3). Install light support units (9) (Ref.
Section 25-20-00).
5. Wall Panels (902 CONFIG) (Business)
(4). Install forward, aft and center roof
A. Wall Panel Removal panels (6) (Ref. Section 25-20-00).
(Ref. Figure 403) 7. Cabin Carpet (Commercial and Business)
NOTE: Most wall panels are held only with A. Cabin Carpet Removal
hook tape fasteners. Others may be held
with hook tape and captive fasteners. (Ref. Figure 403)
(1). Disengage captive fasteners that attach NOTE: Both right and left sides are typical, un
wall panel (19), if applicable. less specified.
(2). Carefully separate hook tape fasteners (1). Remove screws (1) that attach carpet
by pulling panel (19) away from thresholds (2) to floor.
mounting surface. (2). Pull cabin carpet (3) up from hook tape
B. Wall Panel Installation fasteners to remove.
B. Cabin Carpet Installation
(Ref. Figure 403)
(Ref. Figure 403)
(1). Align wall panel (19) and hook tape
fasteners with mating surface hook (1). Press cabin carpet (3) down onto hook
tape attachments. Press surfaces tape fasteners.
together to secure.
(2). Install screws (1) to attach carpet
(2). Engage captive fasteners, if applicable. thresholds (2) and carpet (3) to floor.
Page 403
25-20-00 Original
8. Forward and Aft Roof Panels (3). Install hardware securing roof panel to
(Commercial and Business) support structure.
A. Forward and Aft Roof Panels Removal 10. Area Light, Cabin Roof
(Ref. Figure 403) A. Area Light Removal
(1). Remove hardware that secures roof (Ref. Figure 403)
panels (6) to support structure.
(1). Remove screws (8 and 22) that attach
(2). Disengage pull pins (4) and guide pins area light (10) to light support unit (9)
(5) that hold forward and aft roof and light support plate (21).
panels (6) to adjacent passenger service
(2). Disconnect electrical connection from
units (PSU) (7) and interior perimeter
light (10) and remove.
support structures.
B. Area Light Installation
(3). Remove roof panels (6).
(Ref. Figure 403)
B. Forward and Aft Roof Panels Installation
(1). Install electrical connection to area
(Ref. Figure 403) light (10).
(1). Align forward and aft roof panels (6) (2). Install screws (8 and 22) attaching light
with adjacent passenger service units (10) to light support unit (9) and light
(PSU) (7) and interior perimeter support plate (21).
support structures.
11. Light Support Plate
(2). Engage pull pins (4) and guide pins (5)
to secure panels (6) in place. A. Light Support Plate Removal
(3). Install hardware securing roof panels to (Ref. Figure 403)
support structure.
9. Center Roof Panel (Commercial and area light (10) to light support unit (9)
Business) and light support plate (21).
A. Center Roof Panel Removal (2). Disconnect electrical connection from

light (10) and remove.
(Ref. Figure 403)
(1). Remove hardware that secures roof that attach support plate (21) to roof
panel (6) to support structure. mounting surface.
(2). Remove pull pins (4) and guide pins (5) B. Light Support Plate Installation
that hold center roof panel (6) between (Ref. Figure 403)
passenger service units (PSU) (7) and
interior perimeter support structures. (1). Prepare surface for electrical bond (Ref.
CSP-SPM).
(3). Remove roof panel (6).
B. Center Roof Panel Installation attaching light support plate (21) to
roof mounting surface.
(1). Align center roof panel (6) with adja
cent passenger service units (PSU) (7) (3). Install electrical connection to area
and interior perimeter support struc light (10).
tures.
(4). Install screws (8 and 22) attaching light
(2). Install pull pins (4) and guide pins (5) (10) to light support unit (9) and light
to secure panel (6) in place. support plate (21).
Page 404
Original 25-20-00
12. Light Support Units B. PSU Panels Installation

A. Light Support Units Removal (Ref. Figure 403)
(Ref. Figure 403) (1). Install electrical connections to area

light units (10).
(1). Disengage pull pins (4) and guide pins
(5) that attach center roof panel (6). (2). Install screws (13) and washers (12)
attaching passenger service unit (PSU)
(2). Remove area light unit (10) (Ref. panels (7) to roof structure.
Section 25-20-00).
(3). Install light support units (9) and
(3). Remove screws (11) and washers (12) secure to PSU panels (7) with screws
that attach light support units (9) to (11) and washers (12).
forward and aft passenger service unit
(4). Install forward, aft and center roof
(PSU) panels (7).
panels (6) (Ref. Section 25-20-00).
B. Light Support Units Installation
14. Soundproofing (902 CONFIG) (Business)
(Ref. Figure 403)
A. Soundproofing Removal
(1). Install screws (11) and washers (12) (Ref. Figure 403)
attaching light support units (9) to
forward and aft PSU panels (7). (1). Remove cabin trim interior wall panels.
(2). Install area light unit (10) (Ref. (2). Remove soundproofing (25) panels.
25-20-00).
B. Soundproofing Installation
(3). Engage pull pins (4) and guide pins (5)
attaching center roof panel (6). (Ref. Figure 403)
(1). Install soundproofing (25) panels.
13. Passenger Service Unit (PSU) Panels,
Forward and Aft (Commercial and (2). Install cabin trim interior wall panels.
Business)
15. Closeout Panels
A. PSU Panels Removal
A. Closeout Panels Removal
(Ref. Figure 403)
(Ref. Figure 403)
(1). Remove forward, aft and center roof
(1). Remove forward, center and aft roof
(2). Remove screws (11) and washers (12) (2). Remove light support units (9) (Ref.
that attach light support units (9) to Section 25-20-00).
Fwd and Aft passenger service unit
(PSU) panels (7). Disconnect electrical (3). Remove aft and forward PSU panels (7)
connections from area light units (10). (Ref. Section 25-20-00).
(3). Remove screws (13) and washers (12) (4). Remove screws (11) and washers (12)
that attach Fwd and Aft PSU panels (7) that attach closeout panels (14) to roof
to roof structure. structure.
Page 405
25-20-00 Original
B. Closeout Panels Installation B. Door Panel and Trapping Strip

Installation
(Ref. Figure 403)
(Ref. Figure 403)
attaching closeout panels (14) to roof (1). Install screws (15) and washers (12)
structure. (decorative caps and washers, if
applicable) attaching trapping strip (17)
(2). Install aft and forward PSU panels (7) and lower door panel (16) to door frame
(Ref. Section 25-20-00). (18).
(3). Install light support units (9) (Ref. 17. Window Reveal
Section 25-20-00).
A. Window Reveal Removal
(4). Install forward, center and aft roof
panels (6) (Ref. Section 25-20-00). (Ref. Figure 403)
(1). Remove screws (15) that attach
16. Door Panel and Trapping Strip trapping strip (17) to door frame (18).
A. Door Panel and Trapping Strip Removal (2). Remove screws (15) and washers (12)
that attach window reveal (20) to door
(Ref. Figure 403)
frame (18).
(1). Remove (decorative caps and washers, B. Window Reveal Installation
if applicable) screws (15) and washers
(12) that attach lower door panel (16) (1). Align window reveal (20) with door
and trapping strip (17) to door frame frame (18) holes and install screws (15)
(18). and washers (12).
(2). Remove door panel (18) and trapping (2). Install screws (15) attaching trapping
strip (17). strip (17) to door frame (18).
Page 406
Original 25-20-00
23
23
14
12 (43 PL) 14
21 14
11 (43 PL) 7
13
7 12
9 21
6
12
22
10 6
18 11
8 6
2 12
1 4 5 11
20
3
17
12
15
25
24
16
19
25 25
19
25
9G25009B
Figure 403. Cabin Compartment Interior Trim Commercial/Business
Page 407
25-20-00 Original

1. SCREW 14. CLOSEOUT PANEL
2. CARPET THRESHOLD 15. SCREW
3. CABIN CARPET 16. LOWER DOOR PANEL
4. PULL PIN 17. TRAPPING STRIP
5. GUIDE PIN 18. DOOR FRAME
6. ROOF PANEL 19. INSULATION (WALL) PANEL
7. PASSENGER SERVICE UNITS (PSU) 20. WINDOW REVEAL
8. SCREW 21. LIGHT SUPPORT PLATE
9. LIGHT SUPPORT UNIT 22. SCREW
10. AREA LIGHT 23. ACOUSTIC INSULATION
11. SCREW 24. PULL STRAP
12. WASHER 25. SOUNDPROOFING
13. SCREW
18. Cabin Carpet (Utility) (3). Install screws (4) and washers (5)
securing vent gasper closeouts (6) to
A. Cabin Carpet Removal roof support brackets.
(Ref. Figure 404)
20. Area Light, Cabin Roof
(1). Remove screws (1) that attach carpet
thresholds (2) to floor. A. Area Light Removal
(2). Pull cabin carpet (3) up from hook tape (Ref. Figure 404)
fasteners to remove.
B. Cabin Carpet Installation area light (11) to light support plate
(12).
(1). Press cabin carpet (3) down onto hook
tape fasteners. (2). Disconnect electrical connection from
light (11) to remove.
(2). Install screws (1) to attach carpet
thresholds (2) and carpet (3) to floor. B. Area Light Installation
19. Roof Panel (Utility) (1). Install electrical connection to area
A. Roof Panel Removal light (11).
(Ref. Figure 404) (2). Install screws (9 and 10) attaching light
(11) to light support plate (12).
attach vent gasper closeouts (6) to roof 21. Light Support Plate
support brackets.
A. Light Support Plate Removal
(2). Disengage hardware that attaches roof
panel (7) to closeout panels (8). (Ref. Figure 404)
(3). Remove roof panel (7) by pulling down
(1). Remove roof panel (7) (Ref. Section
from hook tape fasteners. 25-20-00).
B. Roof Panel Installation
(1). Align roof panel (7) with hook tape area light (11) to light support plate
fasteners in closeout panels (8) and (12).
press together to secure.
(2). Engage hardware that attaches roof attach light support plate (12) to
panel (7) to closeout panels (8). support brackets.
Page 408
Original 25-20-00
B. Light Support Plate Installation (2). Install light support plate (12) (Ref.
Section 25-20-00).
(1). Prepare surface for electrical bond (Ref.
CSP-SPM). (3). Install roof panel (7) (Ref. Section
(2). Install screws (4) and washers (5) 25-20-00).
securing light support plate (12) to
support brackets. 23. Door Panel and Trapping Strip
(3). Install screws (9 and 10) securing area
A. Door Panel and Trapping Strip Removal
light (11) to light support plate (12).
(4). Install roof panel (7) (Ref. Section (Ref. Figure 404)
25-20-00).
(1). Remove screws (4) that attach trapping
22. Closeout Panels strip (16) to door frame (18).
(Ref. Figure 404) that attach lower door panel (17) to
door frame (18).
(1). Remove roof panel (7) (Ref. Section
25-20-00). (3). Remove door panel (17) and trapping
(2). Remove light support plate (12) (Ref. strip (16).
Section 25-20-00).
B. Door Panel and Trapping Strip
(3). Remove screws (4) and washers (5) that Installation
attach closeout panels (8) to roof
support structure. (1). Install screws (14) and washers (15)
B. Closeout Panels Installation attaching lower door panel (17) to door
frame (18).
attaching closeout panels (8) to roof (2). Install screws (4) attaching trapping
support structure. strip (16) to door frame (18).
Page 409
25-20-00 Original
12 8
7
8 5 (4 PL)
4 (4 PL)
5 (45 PL)
5 (4 PL) 6
4 (45 PL) 4
4 (4 PL) 11 5
1 (9 PL) 2 8
6 9 (2 PL) 10 (2 PL)
2
3
18
16
4 (5 PL)
18 17
14
15
19
13
13
13
13
9G25015A
Figure 404. Cabin Compartment Interior Trim Utility
Page 410
Original 25-20-00

1. SCREW 11. AREA LIGHT
2. CARPET THRESHOLD 12. LIGHT SUPPORT PLATE
3. CABIN CARPET 13. INSULATION PANEL
4. SCREW 14. SCREW
6. VENT GASPER CLOSEOUT 16. TRAPPING STRIP
7. ROOF PANEL 17. LOWER DOOR PANEL
8. CLOSEOUT PANEL 18. DOOR FRAME
9. SCREW 19. PULL STRAP
10. SCREW

25-20-00 Original
CABIN COMPARTMENT
INSPECTION/TEST
1. Cabin Compartment (6). Examine seat fabric for tears, cuts, or
other damage.
A. Seat Inspection (Area 2)
(a). The maximum permitted separation
(1). Examine cabin seats for correct instal at fabric seams, 0.875 in. (22.23
lation and condition. mm) (across seam) and a width of 1
(2). Examine quick disconnect mechanism in. (25.4 mm) (along seam).
on cabin seat main tubes for correct
operation and damage. (7). Examine seat support straps for wear,
cuts, or tears. None permitted.
(a). Make sure they engage and lock into
anchors when seat is installed. B. Seat Energy Absorption System (EAS)
Maximum play permitted at upper Inspection
and lower attach points, 0.020 in.
(Ref. Figure 601)
(0.508 mm).
(b). Examine roof and floor anchors for (1). Measure the clearance between the
correct installation and condition. fixed fitting and sliding fitting on the
Maximum scratch and gouge depth main tube on the two sides of each
permitted, 0.012 in. (0.305 mm). cabin seat. Maximum clearance
permitted, 0.1 in. (2.54 mm)
(3). Examine Energy Absorption System
(EAS) aluminum tubes for condition. C. Seat Restraint System Inspection
No deformation or cracks are permitted. (Area 2)
No damage through external coating is
(1). Examine restraint system for correct
permitted.
installation and operation as follows:
(a). Make sure aluminum tube is aligned
with seat main tube. (a). Belt adjust mechanism for correct
operation and condition. No damage
(b). Examine plastic cap that attaches permitted.
EAS aluminum tube to seat main
tube. Damage to cap can be an (b). Area of belt that goes through adjust
indication EAS aluminum tube is mechanism for wear. No damage to
deformed or damaged. No damage or belt permitted.
deformation permitted.
(c). Belts for cuts, nicks, tears, or other
(4). Repair corrosion to a maximum depth damage. No damage permitted.
of 0.010 in. (0.254 mm) (Ref. CSP-
SPM). (d). Do a check for correct operation of
buckles, latch and release. No defects
(5). Make sure seat fabric is clean. permitted.
Page 601
0.1 IN
FIXED FITTING (2.54 mm)
ASSEMBLY
SLIDING FITTING
9G25026
Figure 601. Seat EAS Inspection
Page 602
D. Trim Inspection (Area 2) (3). Make sure interior lights are service
able and electrical connections have no
damage. No damage permitted.
(Ref. CSPSPM) (4). Examine carpet for cuts, tears, correct
Item Nomenclature installation, or other unserviceable
conditions.
C714 Tape, Adhesive, Clear (5). If installed, examine overhead passen
ger service units for correct operation
and damage. No damage permitted.
(1). Examine soft insulation panels or hard
wall panels for condition and wear. (a). Make sure air vent gaspers move
freely and are not clogged.
(a). Make sure panels are clean and have (b). Do a operational check of each light.
no stains, tears, or corrosion on metal
components. For procedures to clean (6). Make sure you can read the placards
(Ref. CSP-SPM). and decals.
(7). Make sure placards and decals are
NOTE: Repair minor damage to panels, use correctly installed.
clear adhesive tape (C714).
E. Seat Operational Test
Adhesive Paste, Acrylic (C422)
(1). Make sure seats fold up into their
stowed position and attach with strap.
F. Seat Restraint System Operational Test
(1). Latch lap belt and shoulder harness.
(2). Examine panels and fuselage structure Make sure latch mechanism operates
for missing or loose hook and loop tape correctly. Make sure straps do not
fasteners. If loose, bond with adhesive disengage from buckle unless released
paste (C422). by buckle operation.
Page 603
Page 604
Section
255000
Baggage
Compartment
Interior Trim
BAGGAGE COMPARTMENT INTERIOR TRIM

1. Baggage Compartment Interior around the anti-torque fan assembly. A
portion of the roof insulation can be removed
(Ref. Figure 1) to gain access to the electrical services panel
The baggage compartment is lined with which is installed in the roof structure. A
insulation panels installed to the roof and side universal area light is installed to the left
walls and carpet material secured to the floor hand side wall to provide light to the baggage/
area. Soundproofing was added with the cargo compartment. A side stowage pocket on
business interior option (902 CONFIG) the right hand side panel is provided for the
between the baggage and cabin areas and flyaway equipment.
Page 1
25-50-00 Original
ROOF INSULATION PANEL
HOOK TAPE
SIDE INSULATION PANEL
HOOK
TAPE
HOOK
TAPE
HOOK TAPE HOOK

TAPE
THRESHOLD
CARPET
HOOK
TAPE
HOOK
TAPE
HOOK
TAPE HOOK
HOOK TAPE
TAPE
HOOK
TAPE 9G250051A
Figure 1. Baggage Compartment Interior Trim (Sheet 1 of 2)
Page 2
Original 25-50-00
NOTE
LIGHT ASSEMBLY
INTERIOR
NOTE DOOR PANEL
DOOR LATCHING
MECHANISM
HOOK TAPE
BAGGAGE DOOR
ASSEMBLY
HOOK TAPE
PANEL ASSEMBLY
INTERIOR
SOFT PANEL
NOTE: STANDOFFS AND ATTACHING HARDWARE ON ORIGINAL CONFIGURATION.

9G250052A
Figure 1. Baggage Compartment Interior Trim (Sheet 2 of 2)
Page 3/(4 blank)

25-50-00 Original
BAGGAGE COMPARTMENT INTERIOR

FAULT ISOLATION
1. Interior Troubleshooting Troubleshooting tables should be used with the
brief summary of baggage compartment detailed procedures referred to in this and
interior faults, which may be encountered other chapters of the manual.
(Ref. Table 101).
Comprehensive wiring diagrams are available
in the Rotorcraft Maintenance Manual
CSP-900RMM-3 (Ref. Section 98-40-00).
Loose /Unsecured interior Loose hook tape. Remove loose hook tape and 255000
panel. replace.
Unsecured fastener or Determine unsecured fastener

provisioning attachment. location and replace.

25-50-00 Original
BAGGAGE COMPARTMENT INTERIOR TRIM

General: Some components in this section (2). Engage captive fasteners (3) attaching
require removal of soft interior insulation closeout panels (2).
panels in order to gain access to the compo
nents attaching hardware. The following (3). Press soft insulation panels (1) up
procedure explains the basic task of their against hook tape fasteners to secure.
removal and installation.
NOTE: Most soft insulation panels are held 3. Carpet Panel
only with hook tape fasteners. Others may
be held with hook tape and captive fasten A. Carpet Panel Removal
ers.
(Ref. Figure 401)
1. Insulation Panel (Trim)
(1). Remove screws (4) that attach carpet
A. Insulation Panel Removal threshold (5) to floor structure.
(Ref. Figure 401)
(2). Pull carpet panel (6) up from hook tape
(1). Disengage fasteners, if applicable. fasteners.
(2). Carefully pull soft insulation panels (1) (3). Remove carpet panel (6).
away from hook tape fasteners.
(3). Remove panels (1). B. Carpet Panel Installation
B. Insulation Panel Installation (Ref. Figure 401)

(Ref. Figure 401) (1). Press carpet panel (6) down onto hook
(1). Press soft insulation panels (1) up tape fasteners.
against hook tape fasteners to secure.
(2). Install screws (4) attaching carpet
(2). Engage fasteners, if applicable. threshold (5) to floor structure.
2. Closeout Panel Assemblies 4. Area Light Assembly

A. Area Light Assembly Removal
(Ref. Figure 401)
(Ref. Figure 401)
(1). Remove (specific) soft insulation panels
(1) that may cover closeout panel (2). (1). Remove screws (9 and 12) that attach
(2). Disengage captive fasteners (3) that lens (10) to area light assembly (11).
attach closeout panels (2) to mounting
surfaces. (2). Remove screws (13) and washers (14)
that attach light cover (15) to mounting
(3). Remove closeout panels (2). bracket (16).
B. Closeout Panels Installation (3). Detach electrical connection from light
(Ref. Figure 401) assembly (11).
(1). Align closeout panel (2) with mounting (4). Remove nuts (17) and washers (14)
surfaces. that attach mounting bracket (16).
Page 401
25-50-00 Original
B. Area Light Assembly Installation (3). Remove trim panel (7).

(Ref. Figure 401) B. Door Trim Panel Installation
(1). Install nuts (17) and washers (14) (Ref. Figure 401)
attaching mounting bracket (16) to
airframe. (1). Align door trim panel (7) with inside
door assembly hook tape fasteners (8)
(2). Attach electrical connection to area (new configuration).
light assembly (11).
(2). Press panel (7) down against fasteners
(3). Install screws (13) and washers (14) (8) to secure or install washers (18) and
attaching light cover (15) to mounting screws (19) (original configuration)
bracket (16). attaching panel (7) to inside door
assembly.
(4). Install screws (9 and 12) attaching lens
(10) to area light assembly (11). (3). Install door strut assembly and strut
bracket (Ref. Section 52-00-00).
5. Door Trim Panel
6. Soundproofing Kit
A. Door Trim Panel Removal
A. Soundproofing Removal
(Ref. Figure 401)
(1). Remove trim insulation panels.
(1). Remove door strut assembly and strut
bracket (Ref. Section 52-00-00). (2). Remove components of soundproofing
kit (20).
(2). Remove screws (19) and washers (18) (if
installed - original configuration) that B. Soundproofing Installation
attach door trim panel (7) or pull trim (1). Install components of soundproofing kit
panel (7) up and away from hook tape (20).
fasteners (8) (new configuration) from
inside door assembly. (2). Install trim insulation panels.
Page 402
Revision 3 25-50-00
17
13
14 12 14
9
ROTATED
13
14
15
16
14 13
11
10 NOTE
19
18
1
1
5
4
6 8
20
NOTE: STANDOFFS AND ATTACHING HARDWARE 1

ON EARLY CONFIGURATION.
9G25016B
Figure 401. Baggage Compartment Interior Trim/Soundproofing
Page 403
25-50-00 Original

1. INSULATION PANEL 11. AREA LIGHT ASSEMBLY
2. CLOSEOUT PANEL 12. SCREW
3. FASTENER 13. SCREW
4. SCREW 14. WASHER
5. CARPET THRESHOLD 15. LIGHT COVER
6. CARPET 16. MOUNTING BRACKET
7. TRIM PANEL 17. NUT
8. HOOK TAPE 18. WASHER
9. SCREW 19. SCREW
10. LENS 20. SOUNDPROOFING KIT
Page 404
Original 25-50-00
BAGGAGE COMPARTMENT INTERIOR

INSPECTION / TEST
1. Interior Trim Inspection Adhesive Paste, Acrylic (C422)
(Ref. CSPSPM)
Item Nomenclature
C714 Tape, Adhesive, Clear (2). Inspect panels and fuselage structure
for missing or loose hook tape fasteners.
If loose, reattach to structure with
(1). Inspect baggage area soft insulation adhesive paste (C422).
panels for general condition and wear.
(a). Verify that insulation panels are (3). Inspect carpeting for cuts, tears,
clean and free from discoloration, security or other unserviceable condi
stains, tears or corrosion on metallic tions. Repair as necessary.
components. For cleaning procedures
(Ref. CSP-SPM). (4). Verify that interior light is serviceable
NOTE: Minor repairs may be made to these and electrical connections are free from
panels to prevent continuing degradation by damage or deterioration.
using clear adhesive tape (C714) to cover
the damaged area and draw a tear or hole (5). Inspect placards and decals for security
closed. and legibility.

25-50-00 Original
Section
255500
Cargo Hook System
CARGO HOOK SYSTEM

1. Description 2. Operation
There is a load indication feature displayed on
(Ref. Figure 1)
the IIDS alphanumeric display thru a menu
selection.
The cargo hook system is a sling-mounted
assembly attached to provisions on the two The primary means of releasing the load from
forward and two aft landing gear hard the cargo hook is via an electrical release
mounting points. switch located on either the RH of LH com
mand station cyclic grip. The release switch,
The cargo hook system has a load capacity of: when actuated, will annunciate HOOK
OPEN on the IIDS display. Secondary means
of releasing the load is through a mechanical
(Post-SB900-073, Part 1) Up to 2200 lb
control also mounted on the cyclic stick of the
(998 kg) with aft LH saddle assembly (PN
command station.
900F2361610-103/-105) and aft RH saddle
assembly (PN 900F2361610-104/-106) The system was designed for easy installation/
installed. removal by means of two forward and two aft
shear pins secured by quick-release pins, two
(Post-SB900-073, Part 2) Up to 3000 lb quick-release electrical connectors (electrical
(1361 kg) with aft LH saddle assembly (PN release and load indication harness) and a
900F2361610-107) and aft RH saddle quick-release mechanical release control cable
assembly (PN 900F2361610-108) installed. connector.
Page 1
note: MAKE SURE QUICK

RELEASE PIN HEAD FACES
`ÙP'' AFTER INSTALLATION
MAX WORKING
LOAD 2200 LB
CARGO HOOK PLACARD
(IF INSTALLED REF. SB900-073)
AFT Saddle clamp LH AFT LANDING

GEAR FITTING
QUICK
RELEASE PIN QUICK RELEASE PIN
(SEE NOTE) (SEE NOTE)
PIN LINK LINK ASSEMBLY
LINK
ASSEMBLY CABLE CABLE
FORWARD
PIN LINK
fwd saddle clamp
LH FWD LANDING
RH AFT LANDING GEAR FITTING
GEAR FITTING
RH FWD LANDING
GEAR FITTING
CYCLIC STICK
CARGO HOOK SERVICE LOOP
MECHANICAL
RELEASE LEVER
LOAD BEAM
LOAD INDICATOR
ELECTRICAL CONNECTOR MANUAL RELEASE
ELECTRICAL RELEASE CABLE CONNECTION
CONNECTOR
MANUAL CARGO HOOK
RELEASE
ELECTRIC CARGO
HOOK RELEASE
cyclic grip rotated 9G25014C
Figure 1. Cargo Hook System
Page 2
CARGO HOOK SYSTEM

FAULT ISOLATION
1. Cargo Hook System Troubleshooting wiring diagrams, serviceability checks, and
other detailed procedures referred to in this
(Ref. Table 101) and other chapters of the manual.
The troubleshooting procedures of Table 101
are a brief summary of cargo hook system The wiring diagrams are in the Rotorcraft
faults, which possibly can occur. Use Table 101 Maintenance Manual (ref. CSP-900RMM-3,
with simplified system schematics, electrical Section 98-40-00).
Table 101. Cargo Hook System Troubleshooting
Cargo hook release operates Defective hook release Replace switch. 255500
manually (by manual release switch.
lever) but fails to operate
electrically (by release
switch).
Faulty ground. Attach ground wire. 980000
Faulty cargo hook circuit Replace circuit breaker. 960000
breaker.
Faulty wiring. Repair or replace wiring. 980000

Cargo hook operates Manual release cable Adjust cable. 255500
electrically (by release adjusted incorrectly.
switch) but fails to operate
mechanically (by manual
release lever).
Broken or disconnected Replace or attach cable. 255500
cable.
Defective hook assembly. Replace hook assembly. 255500

SENSFALT=15 Rotorcraft is not configured Make sure shorting plug 953000
for cargo hook and shorting resistance is 346 to 354 ohms
plug is not installed or is and correctly installed (ref.
wrong resistance. Cargo Hook Excitation Test).
Sensor excitation failure. Do the Sensor Excitation Test. 953000

Replace a faulty sensor.
IIDS defective. Do the Sensor Excitation Test. 953000

Replace a defective IIDS.
Faulty wiring. Do the Sensor Excitation Test. 953000

Repair or replace faulty wiring.
Page 101
Page 102
CARGO HOOK SYSTEM

1. Cargo Hook System C. Cargo Hook Reattachment
A. Cargo Hook System Removal (Ref. Figure 401)

(1). Install bolt (15), washer (19) and nut
(Ref. Figure 401)
(18) attaching load cell (20) to hook
connector (14).
Power Off
(18) attaching load cell (20) to cargo
hook (7).
(3). Install bolts (12), washers (11) and nuts
(1). Verify all power is removed from (10) attaching clevis' (13) to hook
aircraft (Ref. Section 96-00-00). connector (14).
(2). Disconnect cargo hook electrical (4). Tighten nuts and install new cotter
connector (1), load indicator electrical pins.
connector (2) and mechanical release
control cable connector (3). (5). Install cable clamps (21) attaching
connector lines (1, 2 and 3) to cargo
(3). Remove quick release pins (4) from Fwd hook cable (6).
and Aft pin links (5). D. Cargo Hook System Installation
(4). Remove pin links (5) that attach cargo (Ref. Figure 401)
hook cables (6) and cargo hook (7) to
landing gear saddle clamp assemblies Power Off
(8)
B. Cargo Hook Detachment
(Ref. Figure 401) (1). Align cargo hook cable attach hardware
with landing gear saddle clamp assem
(1). Remove cable clamps (21) that attach blies (8) and install pin links (5).
connector lines (1, 2 and 3) to cargo
hook cable (6). (2). Install quick release pins (4) into Fwd
and Aft pin links (5).
(2). Remove and discard cotter pins (9).
Remove nuts (10), washers (11) and (3). Connect cargo hook electrical connector
bolts (12) that attach clevis' (13) to (1), load indicator electrical connector
hook connector (14). (2) and mechanical release control cable
connector (3).
(4). Restore power to aircraft (Ref. Section
Remove nut (18), washer (19) and bolt
96-00-00).
(16) that attach load cell (20) to cargo
hook (7). (5). Verify cargo hook Vne card is installed
in aircraft (Ref. Section 11-00-00).
Remove nut (18), washer (19) and bolt (6). Perform Set Cargo Hook (Load Cell)
(15) that attach load cell (20) to hook Calibration Code Menu (Ref.
connector (14). CSP-900RMM-3, Section 95-30-00).
Page 401
MAX WORKING
LOAD 2200 LB
CARGO HOOK PLACARD
(IF INSTALLED REF. SB900-073)
8
4
8
5
1
13 (2 PL) 9 (2 PL)
11 (2 PL)
10 (2 PL)
7
19 17
3
18 2
12 (2 PL) 21
14
15
20 17
18
19 note: ENSURE QUICK RELEASE
16 PIN HEAD FACES `ÙP''
AFTER INSTALLATION
9G25012B
1. CARGO HOOK ELECTRICAL CONNECTOR 11. WASHER

2. LOAD INDICATOR ELECTRICAL CONNECTOR 12. BOLT
3. MECHANICAL RELEASE CONTROL CABLE 13. CLEVIS
CONNECTOR 14. HOOK CONNECTOR
4. QUICK RELEASE PINS 15. BOLT
5. FWD AND AFT PIN LINKS 16. BOLT
6. CARGO HOOK CABLES 17. COTTER PIN
7. CARGO HOOK ASSEMBLY 18. NUT
8. LANDING GEAR SADDLE CLAMP ASSEMBLIES 19. WASHER
9. COTTER PIN 20. LOAD CELL
10. NUT 21. CABLE CLAMP
Figure 401. Cargo Hook System
Page 402
2. Cargo Hook Cockpit, Mechanical Release 3. Cargo Hook Cockpit, Mechanical Release
Cable Assembly Bracket
NOTE: Pilot or copilot cargo hook mechanical A. Cargo Hook Cockpit, Mechanical Release
release cable attachments are the same ex Bracket Removal
cept for routing through fuselage.
(Ref. Figure 402)
A. Cargo Hook Cockpit, Mechanical Release
(1). Remove cargo hook cockpit mechanical
Cable Assembly Removal release cable assembly handle (1).
(Ref. Figure 402) (2). Remove jam nut (4) and washer (5) that
attach cable assembly (3) to cargo hook
(1). Remove cargo hook cockpit mechanical cockpit mechanical release bracket (2).
release cable assembly handle (1).
(3). Remove nut (8) that attaches bracket
(2). Remove jam nut (4) and washer (5) that (2) to cyclic tube.
attach cable assembly (3) to cargo hook
cockpit mechanical release bracket (2). (4). Remove bracket (2).
(3). Remove tiedown straps (12). B. Cargo Hook Cockpit, Mechanical Release
Bracket Installation
(4). Remove nuts (9), washers (6 and 7) and
bolts (10) that attach loop clamps (11) (Ref. Figure 402)
to cable support clips (13).
(1). Install cargo hook cockpit mechanical
(5). Disconnect cable assembly (3) attach release bracket (2) and attach with nut
point at the fuselage doubler (14). (8). Torque nut.
(2). Install jam nut (4) and washer (5)
(6). Remove cable assembly (3) from under
attaching cargo hook cockpit mechani
floor fuselage routing.
cal release cable assembly (3) to
B. Cargo Hook Cockpit, Mechanical Release bracket (2).
Cable Assembly Installation (3). Install cable assembly handle (1).
(Ref. Figure 402) 4. Cable Support Clip
(1). Route cargo hook mechanical release A. Cable Support Clip Removal
cable assembly (3) under floor and
secure through loop clamps (11). (Ref. Figure 402)
(2). Install bolts (10), washers (6 and 7), (1). Remove nuts (9), washers (6 and 7) and
and nuts (9) attaching loop clamps to bolts (10) that attach loop clamps (11)
cable support clips (13). Torque nuts. and cable support clips (13) to the
plough beam.
(3). Connect cable assembly (3) at the
fuselage doubler (14). (2). Separate loop clamps (11) from clips
(13) and remove.
(4). Attach cable assembly (3) to cargo hook
B. Cable Support Clip Installation
cockpit mechanical release bracket (2)
by installing washer (5) and jam nut (Ref. Figure 402)
(4).
(1). Join loop clamps (11) and cable support
(5). Install cargo hook cockpit mechanical clips (13).
release cable assembly handle (1).
(2). Install bolts (10), washers (6 and 7) and
(6). Secure cable assembly (3) with tiedown nuts (9) attaching loop clamps (11) and
straps (12). clips (13) to plough beam. Torque nuts.
Page 403
25-55-00 Original
1
2
3 5
3 2
12 8
12
4
11
10
13
14
6
13
PILOT'S SIDE SHOWN
COPILOT'S SIDE SIMILAR
9G25013
1. HANDLE 8. NUT
2. BRACKET 9. NUT
3. CABLE ASSEMBLY 10. BOLT
4. JAM NUT 11. LOOP CLAMP
5. WASHER 12. TIEDOWN STRAP
6. WASHER 13. CABLE SUPPORT CLIP
7. WASHER 14. FUSELAGE DOUBLER
Figure 402. Cargo Hook Mechanical Release
Page 404
Original 25-55-00
5. Cargo Hook, Wire Harness W314 Adhesive, Epoxy (C408)

Replacement
A. Wire Harness W314 Removal
(Ref. Figure 403)
Power Off
WARNING
(4). Apply epoxy adhesive (C408) or epoxy

adhesive (C411) around edges of
(1). Verify all power is removed from
doubler (1) and position on inside floor
aircraft (Ref. Section 96-00-00).
of fuselage.
(2). Gain access by removing center access NOTE: Rivets may be installed from either side
panel (B142) (Ref. Section 06-00-00) of structure.
(3). Disconnect plug P600 from receptacle (5). Install rivets (2) attaching doubler (1)
J600. to floor of fuselage.
(4). Remove screws (7), washers (8) and NOTE:
nuts (9) that attach connectors (4 and When installing wire harness W314 (3)
5) to doubler (1). make provision for drip loops and excess
slack.
(5). Remove wire harness W314 (3).
Connector keyway is to be positioned to
NOTE: If aircraft is going to be operated with wards front of aircraft when mounted.
out wire harness W314, install shorting (6). Prepare surface for electrical bond (Ref.
plug (10) to receptacle J600. CSP-SPM).
B. Wire Harness W314, Initial Installation (7). Mount connectors (4 and 5) to surface of
doubler (1) and secure with screws (7),
(Ref. Figure 403) washers (8) and nuts (9).
(8). Mount connector (6) to surface of
Consumable Materials doubler (1).
(Ref. CSPSPM)
Item Nomenclature (9). Fillet seal around base of connectors (4
and 5) using sealant (C216) (Ref.
C216 Sealant, Fuel Resistant
CSP-SPM).
C411 Adhesive, Epoxy (10). Connect plug P600 to receptacle J600
(J600 receptacle comes from existing
W125 wire harness, already installed).
Power Off (11). Ground shield of harness (3) to mount
WARNING
ing hardware of J600 receptacle.
(12). Restore power to aircraft (Ref. Section
96-00-00).
(1). Verify all power is removed from (13). Install center access panel (B142) (Ref.
aircraft (Ref. Section 96-00-00). Section 06-00-00).
(2). Gain access by removing center access NOTE: If aircraft is going to be operated with
panel (B142) (Ref. Section 06-00-00) out external cargo hook system (hook and
cables) installed, transfer dust cap (12) and
(3). Match drill holes from doubler (1) to shorting plug (11) from dummy receptacles
fuselage. (13) to connectors (4 and 5).
Page 405
25-55-00 Original
RBL
0.51
13
FS
155
3 P600
J600
VIEW LOOKING UP AT (GROUND)

BOTTOM OF AIRCRAFT
9
1
(EXISTING W125 WIRE

8 PL 8
HARNESS, INSTALLED)
6
7 10
5
11
4 12
2 (20 PL) 9G25-021A
1. DOUBLER 8. WASHER
2. RIVET 9. NUT
3. WIRE HARNESS W314 10. SHORTING PLUG
4. ELECTRICAL RELEASE CONNECTOR 11. SHORTING PLUG
5. LOAD INDICATOR CONNECTOR 12. DUST CAP
6. MECHANICAL RELEASE CONNECTOR 13. DUMMY RECEPTACLE
7. SCREW
Figure 403. Wire Harness W314, Cargo Hook
Page 406
Original 25-55-00
CARGO HOOK SYSTEM

INSPECTION / TEST
1. Cargo Hook System Inspections (a). Make sure the release action fully
retracts when activated under
A. General Inspection various load and attitude conditions.
(1). Examine the connections between the B. Cargo Hook Inspection
cargo hook sling and the rotorcraft.
(1). Examine cargo hook for dirt, grit, or
(a). Examine hardware for damage or foreign objects that can bind or cause
indications of possible fatigue. incorrect operation.
(b). No scoring or play is permitted on (2). Examine cargo hook for scratches to the
this attached hardware. surface finish.
(2). Examine cable sling assembly for (a). If there are scratches that go through
fraying, wear, or other damage. the protective finish layer and into
the base material, replace the cargo
(a). No indication of damage permitted. hook.
(3). Examine electrical release, and load (3). Examine the surface and the compo
indication wire harness and connectors nents of the cargo hook for oil.
for general condition and security.
(a). If there is oil, clean the cargo hook
(4). Examine mechanical release cable and its components.
housing for nicks, cuts, kinks, or
general damage that can decrease or (4). Examine the cargo hook of pitting or
prevent movement of cable within corrosion.
housing. (a). No pitting or corrosion permitted.
(a). Damage that decreases or prevents (5). Examine the cargo hook for too much
movement is not permitted. grease.
(5). Examine mechanical release connector (a). Grease that has overflowed onto
for general condition and security. components that are not to be
lubricated is not permitted.
(6). Examine hook for cracks, corrosion, and
overall general condition. No damage (6). Examine attached hardware for correct
permitted. installation.
(7). Examine hook for security and function (a). Make sure fasteners and nuts are not
of mechanism. stripped or damaged.
Page 601
INSPECT FOR CRACKS

(BOTH SIDES)
LUG
AFT LH SADDLE (ROTATED 90 CCW)

(AFT RH SADDLE OPPOSITE)
9G25-024
Figure 601. Aft Saddle Inspection
Page 602
C. Inspection for the Aft LH and Aft RH CSP-SPM, Section 20-40-00, Paint
Saddle Assemblies Removal Chemical).
(Ref. Figure 601) (4). Examine lug to saddle radius area with
a 10X magnification glass for cracks.
(1). Remove aft crosstube cover assembly.
(a). No cracks permitted.
(2). Examine the lugs of aft LH and RH (5). Touch up lug to saddle radius area of
saddles to make sure they are not bent. aft LH and aft RH saddles.
(a). Bent lugs not permitted. (a). Apply a chemical coating (ref.
CSP-SPM, Section 20-40-00,
Make sure that paint stripper Aluminum Alloy, Surface Touch-up
CAUTION does not contaminate bushing or Treatment).
insert of aft LH and RH saddles.
(b). Apply primer and paint to match
(3). Remove paint from lug to saddle radius original (ref. CSP-SPM, Section
area of aft LH and aft RH saddles (ref. 20-30-00).
Page 603
DIM. D
DIM. B
DIM. C
9G2502
Figure 602. Cargo Hook Cable Measurements
Page 604
D. Cable (Wire Rope) Inspection (1). Make sure the CARGO HOOK/HOOK
circuit breaker is pressed to full in the
(Ref. Figure 602). (closed) position.
(1). Examine wire rope for: (2). Make sure the manual release knob on
(a). Dirt, grit, and foreign objects. the left side of the hook assembly is
serviceable without a load attached.
1). If there is contamination, clean the
wire rope. NOTE: This test must be done with the roto
rcraft operated in a low hover position, be
(b). Pitting and corrosion. cause the cargo hook hangs below the land
ing gear skid tubes.
1). No pitting or corrosion permitted.
Make sure that the load beam
(c). Frayed, split, and broken wires. CAUTION on the cargo hook is engaged in
the locked position before a load is attached.
1). No frayed, split, or broken wires
permitted. (3). Attach a load in the cargo hook load
(d). Stretched eyelets. beam and keeper.
1). No stretched eyelets permitted. (4). When the weight is suspended, and the
selection is made on the IIDS panel
(2). Remove cargo hook system (ref. Section menu for HOOK WT., the load indica
25-55-00, Removal/Installation). tion must read HOOK WT. xxxx LBS
on the alphanumeric display.
(3). Measure the length of forward LH and
RH wire ropes (Dimension D). The cargo hook must stay
WARNING closed as it moves through
(a). Dimension D must be 47.125 to all positions of extreme travel (for
47.375 inch (119.698 to 120.333 ward, aft, and side-to-side).
cm).
(5). With a lead line attached to the cargo
(b). If the measurement is not within the hook, with the ground personnel a safe
specified length, replace the wire distance from the rotorcraft, pull aft,
rope. downward, forward, and side-to-side
(4). Measure the length of aft LH (Dimen with an approximate 30 degree angle of
sion B) and RH (Dimension C) wire displacement on the hung load.
ropes.
(6). Activate electrical release on the
(a). Dimension C must be 37.195 to command station cyclic control grip to
37.445 inch (94.475 to 95.110 cm). release hung load.
(b). Dimension B must be 37.195 to (a). The load beam must release the
37.445 inch (94.475 to 95.110 cm). attached load.
(c). If the measurement is not within the (7). After the aircraft has landed, reattach
specified length, replace the wire load on hook.
rope.
(8). Return to low hover to test mechanical
2. Cargo Hook System Tests release lever.
A. Cargo Hook System Functional Test (9). With the aircraft in a low hover
position, activate mechanical release
NOTE: Do the functional test procedure when handle to release hung load.
the cargo hook system is first installed on
the aircraft and after replacement or over (a). The load beam must release the
haul of the hook system. attached load.
Page 605
B. Cargo Hook System Operational Test (3). Make sure the manual release knob on
the left side of the hook assembly is
NOTE: Do the operational test procedure when operational without a load attached.
it is necessary to make sure that the cargo (4). On ELECTRICAL MASTER panel,
hook system release mechanisms operate set POWER switch to BAT/EXT
correctly. position.
(1). Make sure the CARGO HOOK/HOOK (5). Activate electrical release on the
circuit breaker is pressed to full in command station cyclic control grip to
(closed) position. do a check of the release mechanism at
the cargo hook.
(2). Make sure installation and security of (6). Activate mechanical release handle on
mechanical release cable, electrical the command station cyclic control stick
release and load indication wire to do a check of the release mechanism
harness and connectors. at the cargo hook.
Page 606
Section
256000
Emergency
Equipment
EMERGENCY EQUIPMENT
1. Emergency First Aid Kit B. First Aid Kit Contents
Periodically check kit contents to ensure an
A. First Aid Kit adequate supply of medical items. Purchase
individual items locally.
The Emergency First Aid Kit uses a plastic Kit contents include a direction sheet and the
case that meets Federal Aviation Regulation following eight packaged items: adhesive and
(FAR) 27.8530 requirements for fire protection. plain bandage compresses, iodine, swabs,
The case has a 129 cubic inch capacity (3.00 x ammonia inhalants, burn ointment, tourni
5.00 x 8.62 inches) and weighs 1.3 pounds quet, forceps, and scissors. The contents of the
maximum. The case assembly includes a kit meet or exceed the requirements of Federal
handle and a snap fastener. Aviation Authority (FAA) Specification 121,
Appendix A for aircraft with a passenger
The case is opened by off-setting the snap capacity of seven persons or less.
fastener with a counterclockwise movement of
To purchase a replacement kit, contact: The
the thumb and forefinger.
Boeing Company (formerly - McDonnell
Douglas Helicopter Systems)
The kit is located in the right hand side wall 5000 East McDowell Road, Mesa, AZ 85215
stowage pocket of the baggage area. Attn.: New Parts Sales.
Page 1/(2 blank)

25-60-00 Original
EMERGENCY EQUIPMENT
1. First Aid Kit
A. First Aid Kit Inspection
(1). Ensure that kit is stocked with minimal
first aid supplies within shelf life
specified by manufacturer.

25-60-00 Original
Section
256010
Rescue Hoist
EMERGENCY EQUIPMENT
1. Rescue Hoist Variable Speed Controller is a highly efficient
speed control which incorporates the latest
A. Description (PWM) Pulse Width Modulated speed control
techniques. Hoist speed control is accom
The Rescue Hoist System provides a means for plished by a speed command applied to the
lowering and raising personnel from an controller from either the variable speed
airborne helicopter. Operation is from either operator control or the constant speed priority
the crew station or pilot station. The system is override pilots control switch.
comprised of a Hoist Assembly, Pendant
Control Assembly, Electronic Variable Speed Internal power MOSFET switching elements
Controller; interconnection Electrical Control control the amount of average DC voltage
Pendant Cable, and a Pilot Display Assembly. applied to the hoist motor. The greater the
deflection of the thumbwheel on the hoist
Hoist Assembly is a multiple layered type operators Pendant Control Assembly, the
drum design with a cable capacity of 245 feet greater average DC voltage applied to the
of 3/16 dia. 19 x 7 const. (Spin Resistant motor, hence, faster hoisting speeds.
type). Reduction gearing is the planetary type.
Drive train includes a fail-safe mechanically The Controller Assembly being greater than
actuated load brake. Hoist is driven with a 28 95% efficient dissipates minimal power. A heat
VDC electric motor, which includes a totally sink on the side of the controller is used to
enclosed fan cooling and an integral motor remove heat from the controller and installa
brake. tion must be either horizontal with heat sink
facing up or vertical. The controller incorpo
Limit switches are directly coupled to the hoist rates digital electronics which process the hoist
drum to control cable fully extended and limit switch information and limits the hoist
intermediate cable positions (hook approach to speed if an intermediate switch is actuated
aircraft and approach to cable fully-extended and inhibits further hoist movement if a stop
switch). A cable fully retracted switch is built switch is actuated.
into the cable level-wind nut assembly to Controller's digital electronics control the
assure proper homing of the hook when hoist priority of the control inputs from the hoist
is not in service. Redundant switches are used operator or the pilot control. The pilot has
and the mechanical mounting techniques complete priority over the hoist operator and
employed ensure fail-safe operation. the hoist is automatically set to the 600 lb
mode. Pilot's command is fixed-speed with
In the operation of the hoist, the cable rate is
automatic slow downs and stops when the
automatically slowed to a safe speed whenever cable extremes are reached.
the hoist is operated in the cable zone con
trolled by the fail-safe redundant intermediate The controller processes cable position
switch. information from the hoist. Position informa
tion is absolute and will continue to provide
The Hoist also incorporates a cable payout cable position information if power is inter
potentiometer driven by the output of the limit rupted. Cable position information is processed
switch drive mechanism and provides a signal and digitally transmitted to hoist operator's
(proportional to the length in feet of cable control display and pilot's display assembly.
extending from the hoist) to the cable payout
display on the control pendant. Cable payout information is for reference only
and should not be used for helicopter position
A cycle (events) counter is included which is information. The cable payout cannot account
operated by a magnetically actuated reed for cable stretch due to hook loads, therefore,
switch to count drum revolutions. Divide this there is a tolerance at the full-in or full-out of
number by 334 to determine full hoist cycles. plus or minus 3 feet.
Page 1
The controller assembly incorporates the electrical connector for interfacing with the
following safety features: Controller.
Field loss detection circuit - The 250 lb/600 lb control - two-position

controller with inhibit hoist operation if a (maintained) toggle switch used to signal
loss of motor field is detected. the System for either the 250-lb mode or
600-lb mode.
Under voltage lockout - The controller
Direction/Speed control mechanism -
with inhibit hoist operation if the input DC
contains and actuats two switches and a
voltage is <17 VDC.
potentiometer. Two of the switches (one for
Automatic overload detection - The either direction) provide an on-off signal.
controller will detect hoist system overloads Potentiometer is rotated by the control
when high speed is selected by the hoist thumbwheel to provide a speed command
operator. The controller will automatically signal to the Controller Assembly.
shift the hoist into the low speed mode. This ICS control - snap action switch provided
safety feature is recognized by the hoist for connection to the aircraft intercom
operator's motor warning light flashing. The system. Switch is operated by an auxiliary
hoist system with stay in the low speed actuator which protrudes from the back of
mode and when the load is reduced to a safe the hand grip
level the hoist operator can return to the
high speed mode. Cable payout display - provides the hoist
operator with a visual indication on the
Motor warning light - Provides the hoist pendant of how much cable is extended from
operator with a motor overheat indication the hoist in feet. Display is sunlight
by a continuously illuminated motor readable.
warning light. This condition will result
from operating the hoist system under Over Temp/Over Load warning light -
prolonged high temperature environments Warning light provides the hoist operator
that exceed the design limits of the system. with a visual indication of two fault condi
tions: 1) motor over temperature -steady
Pulse by pulse current limit - The light; 2) 250 lb o/l - blinking light. Warning
controller will detect excessive current light is sunlight readable.
requirements from the DC power and limit B. Operation
the amount of power consumed from the
aircraft power system. The Pendant Control Assembly provides hoist
speed and direction signals to the controller.
Cable payout display lamp tests - The The hoist is operated by displacing the
controller upon initial power up will perform thumbwheel in the upward direction to lift a
a lamp test on both cable payout display. load and the downward direction to lower a
This provides the hoist operator and the load. The speed of the hoist is controlled by the
pilot a visual means to verify all display degree of displacement of this thumbwheel and
elements are operational. the thumbwheel is spring loaded to return to
neutral (off) position, hands off.
The Control Pendant Assembly provides the
crewman with freedom of movement while A load selection switch (toggle type) is located
utilizing the following control features: on the right side of the speed/direction
thumbwheel. Positioning the toggle in the
Direction/Speed Control - thumbwheel is downward direction selects operation with
centrally located on the shrouded upper loads up to 250 lbs. This minimum load (250
portion of the hand grip. Except for the ICS lbs.) may be lifted or lowered at speeds up to
switch, all controls are partially guarded to 225 feet per minute. The load selection switch
reduce the possibility of inadvertent is clearly marked defining the 250 lb position
operation. A bracket is provided on the hand (down-ward direction) and the 600 lb in an
grip to facilitate stowing the pendant in the upward position. When the toggle switch is
aircraft. The pendant is equipped with an placed upward in the 600 lb position. the hoist
Page 2
may be operated with loads up to 600 lbs at be selected until the present load is removed
speeds up to 100 feet per minute. from the cable.
An over temperature sensing switch is
With load selection switch actuated to select embedded in the winding of the electric motor
at a temperature critical location. Prolonged
hoist operation in the 250 lb capacity, opera
operation of the hoist system under high
tion at the hoist control with loads applied to
temperature ambients exceeding design limits
hoist cable exceeding 250 lbs will cause the will result in triggering the over motor
motor warning light to flash and in this mode warning light. Critical over temperature
(250 lb selection), the hoist control circuitry conditions within the motor winding results in
will automatically shift and latch the hoist actuation of the sensor which controls the
system to operate in the 600 lb mode. The motor warning light. The motor warning light
hoist system will stay latched in the 600 lb remains illuminated until the motor cools or
mode and the motor warning light will main power to the controller is switched off.
continue to flash until the system is reset by Hoisting operation must be completed at the
switching the load select switch to the 600 lb earliest moment after motor warning light is
mode. Hoist operation can continue in the 600 illuminated, prolonged operation of equipment
lb mode and the high speed mode should not will result in motor damage.
Page 3/(4 blank)

EMERGENCY EQUIPMENT
1. Rescue Hoist Installation Ensure no load is attached to
CAUTION hoist without strut assembly
(23) in position and secured at upper and
A. Install Hoist, Support And Strut
lower points.
(Ref. Figure 1). NOTE: To eliminate possible rattle of strut as

sembly (23) during flight, strut may be
lengthened by rotating rod end bearing (30)
Consumable Materials out one half turn.
(Ref. CSPSPM)
Item Nomenclature (7). Attach lower end of strut assembly (23)
to lower strut fitting assembly with
C318 Primer, Epoxy quick release pin (24).
C702 Lockwire
(8). Attach lanyard (31) with screw (32),
washer (33) and nut (34).
NOTE: If hoist assembly (22) and controller as NOTE: To lower work platforms/steps, when
sembly (16) is attached to support tube (4), performing maintenance on aircraft, re
go to step (7.) move quick release pin (24) from rod end
bearing (30) and move strut assembly (23)
(1). Remove power from aircraft (Ref. aside. Strut assembly must be re-installed
before any load is placed on hoist.
Section 96-00-00).
Primer, Epoxy (C318)
(2). Attach support assemblies (9 and 10) to
control box support assembly (11) with
bolts (12) and washers (13).
(3). Attach support assemblies (9 and 10) (9). Wet install bushings (28) into support
and control box support (11) to bracket tube (4), use epoxy primer (C318).
assemblies (1 and 2) with bolt (14) and
washers (13). (10). Slide support tube (4) onto fitting
assemblies (35) and (36). Secure with
washers (18) and quick release pins
(4). Attach controller assembly (16) to (29).
control box support (11) with bolts (15)
and washers (7). Safety with lockwire (11). Attach upper end of strut assembly (23)
(C702). to lower attach point of aft bracket
assembly (2) with bolt (27), washer (25)
(5). Attach hoist assembly (22) to upper and lock nut (26).
attach points of bracket assemblies (1
and 2) with bolts (17), washers (18) and (12). Attach harness connector P8 to hoist
lock nuts (19). assembly (22) and connector P2 to
controller assembly (16).
(6). Attach hoist assembly (22) to lower (13). Attach connectors P524, P525 and
attach points of bracket assemblies (1 P526 from hoist wire harness to aircraft
and 2) with bolts (20), washers (7) and connectors J524, J525, and J536. (Ref
lock nuts (21). CSP-900RMM-3, 98-30-00)
Page 201
5 (4 PL) REF 2
7 (4 PL) 6 (3 PL)
7 (3 PL)
8 (3 PL) 2
3 9 (2 PL) 27
22 25 X2
1 15 (4 PL) 26
7 (4 PL)
14 (2 PL)
13 (2 PL)
16
11
4
10 (2 PL) 18
20 (2 PL) 42 ( 2 PL )
7 (2 PL X2) 40 (2 PL X 2 )
12 (4 PL) 39 ( 2 PL )
21 (2 PL)
13 (4 PL)
37 ( 4 PL ) 23
38 ( 4 PL )
40 ( 4 PL X 2 ) 29
28
29
18 36
28
FS
230.5
35
REF 22
32 23
33
34
24 LOWER STRUT
FITTING
31 17 (2 PL)
18 (2 PL X2)
19 (2 PL)
30
9K25014A
Figure 1. Hoist System Installation
Page 202

1. FORWARD BRACKET ASSEMBLY 23. STRUT ASSEMBLY
2. AFT BRACKET ASSEMBLY 24. QUICK RELEASE PIN
3. CAP 25. WASHER
4. SUPPORT TUBE 26. LOCK NUT
5. BOLT 27. BOLT
6. BOLT 28. BUSHING
7. WASHER 29. QUICK RELEASE PIN
8. BUSHING 30. ROD END BEARING
9. SUPPORT ASSEMBLY 31. LANYARD
10. SUPPORT ASSEMBLY
32. SCREW
11. CONTROL BOX SUPPORT ASSEMBLY
33. WASHER
12. BOLT
34. NUT
13. WASHER
35. SUPPORT FITTING (FWD)
14. BOLT
15. BOLT 36. SUPPORT FITTING (AFT)
16. CONTROLLER ASSEMBLY 37. BOLT
17. BOLT 38. NUT
19. LOCK NUT 40. BOLT
20. BOLT 41. CLAMP (FWD)
21. LOCK NUT 42. CLAMP (AFT)
22. HOIST ASSEMBLY 43. HANDLE
B. Assist Handel Installation (4). Secure aft clamp (42) to support tube
(4) 19.3 inched from end of support tube
(Ref. Figure 1) (measured along bottom of support tube
to bottom edge of clamp) using bolts
(1). Install fowrard clamp (41) 18 inches (37), washers (39), and nuts (38).
from end of support tube (4) (measured
C. Fairing Installation
along bottom of support tube to bottom
edge of clamp) using bolts (37), washers (Ref. Figure 2)
(39), and nuts (38).
(1). Attach upper fairing (1) to support
(2). Install handle (43) into forward clamp assemblies (2 and 3) and clip assem
(41) using bolt (40), washers (39), and blies (4, 5, 6 and 7) using screws (8) and
nut (38). washers (9).
(2). Attach lower fairing (10) to support
NOTE: Adjust aft clamp (42) position to pre assemblies (2 and 3), clip assemblies (4,
vent binding occuring between clamp and 5, 6 and 7) and upper fairing (1) using
support tube (4). screws (8) and washers (9).
(3). Install aft clamp (42) on handle (43) (3). Attach end cap assembly (11) to upper
using bolt (40), washers (39) and nut and lower fairings (1 and 10) using
(38). screws (8) and washers (9).
Page 203
11
1
3
3 2
9
2
VIEW LOOKING DOWN

5 AT SUPPORT INSTALLATION
4
9
8
10
M25023
A
Figure 2. Hoist Fairing Installation)

1. UPPER FAIRING ASSEMBLY 7. AFT CLIP ASSEMBLY
2. FORWARD SUPPORT ASSEMBLY 8. SCREW
3. AFT SUPPORT ASSEMBLY 9. WASHER
4. FORWARD CLIP ASSEMBLY 10. LOWER FAIRING
5. FORWARD CLIP ASSEMBLY 11. END CAP ASSEMBLY
6. AFT CLIP ASSEMBLY
2. Guard Installation, RH NOTE: This installation is only done when the

aircraft is configured with both Rescue
Hoist and Air Cruiser Emergency Floats to
A. Skid Guard Installation gether.
(1). Position guard (1) and support (2) on
(Ref. Figure 3)
landing gear skid tube (3) and secure in
place with clamps (4).
Consumable Materials Sealing Compound (C207)
(Ref. CSPSPM)
Item Nomenclature
C207 Sealing Compound, Fuel Resistant
C302 Finish Enamel, White (2). Fillet seal around all clamps (4) with
sealing compound (C207).
Page 204
Finish Enamel, White (C302) positions specified in Figure 3. Extend a

minimum of 150 degrees around.
(3). Using white finish enamel (C302), paint

white stripes around skid tube (3) at
INBD
3 1.00
4 (7 PL)
.75 AFT
1.00
1 .75
2
RH LANDING GEAR SKID TUBE
VIEW LOOKING DOWN
M25015
1. SKID GUARD 3. LANDING GEAR SKID TUBE

2. SKID GUARD SUPPORT 4. CLAMP
Figure 3. Landing Gear Skid Guard
B. Float Guard Installation, Rescue Hoist (3). Extend straps (6) around float bag (3)
and thread between float bag support
(Ref. Figure 4) (7) and support rail (8).
(4). Tighten straps (6) to remove slack
(Ref. CSPSPM)
without pulling float guard (1) out of
Item Nomenclature
position. Tie wrap excess as required to
secure loose straps (6).
(5). Secure skid guard (9) in place with
clamps (10).
NOTE: This installation is only done when the
aircraft is configured with both Rescue Sealing Compound (C207)
gether.
(1). Position and secure mating surfaces of
Velcro (hook) (4) on cover (2) to velcro
(pile) (5) area on float bag (3). (6). Fillet seal around all clamps (10) with
(2). Remove original (hoist) skid guard and
replace with (hoist/float) skid guard (9). (7). Locate decals (11) as shown.
Page 205
INBD
6 (4 PL)
11 (2 PL)
RH SIDE, VIEW LOOKING DOWN FWD
A
3
A 1 2
9 UP
10 (6 PL)
RH SIDE, VIEW LOOKING INBOARD FWD
REF 1
REF 6
REF 2
4
5
UP
INBD
7
SECTION A-A 9K25-029
Figure 4. Float Guard Installation
Page 206

1. FLOAT GUARD 7. FLOAT BAG SUPPORT
2. COVER 8. SUPPORT RAIL
3. FLOAT BAG 9. SKID GUARD
4. VELCRO (HOOK) 10. CLAMP
5. VELCRO (PILE) 11. DECAL
6. STRAP
C. Assist Handle Removal (3). Detach harness connector P8 from hoist

assembly (22) and connector P2 from
(Ref. Figure 1) controller assembly (16).
(1). Remove bolt (40), washers (39), and nut (4). Remove bolt (27), washer (25) and lock
(38) securing aft clamp (42) to handle nut (26) and detach upper end of strut
(43). assembly (23) from lower attach point
of aft bracket assembly (2).
(2). Remove bolts (37), washers (39), and
nuts (38) securing aft clamp (42) to Ensure no load is attached to
support tube (4). Remove aft clamp. CAUTION hoist without strut assembly
(23) in position and secured at upper and
(3). Remove bolt (40), washers (39), and nut lower points.
(38) securing forward clamp (41) to
handle (43). Remove handle. (5). Remove washers (18) quick release pins
(29) and bushings (28) into support
(4). Remove bolts (37), washers (39), and tube (4). Slide support tube (4) off
nuts (38) securing forward clamp (41) to fitting assemblies (35) and (36).
support tube (4). Remove forward
clamp. NOTE: If hoist is to be removed from support
tube (4), proceed with steps 6 through 10.
D. Fairing Removal
(6). Remove bolts (20), washers (7) and lock
(Ref. Figure 2) nuts (21). Detach hoist assembly (22)
from lower attach points of bracket
(1). Remove screws (8) and washers (9) and assemblies (1 and 2).
remove end cap assembly (11) from
upper and lower fairings (1 and 10). (7). Remove with bolts (17), washers (18)
and lock nuts (19). Detach hoist
(2). Remove screws (8) and washers (9) and assembly (22) from upper attach points
remove lower fairing (10) from support of bracket assemblies (1 and 2).
assemblies (2 and 3), clip assemblies (4,
5, 6 and 7) and upper fairing (1). (8). Remove lockwire. Remove bolts (15)
and washers (7). Detach controller
(3). Remove screws (8) and washers (9) and assembly (16) from control box support
remove upper fairing (1) to support (11)
assemblies (2 and 3) and clip assem
blies (4, 5, 6 and 7).
Detach support assemblies (9 and 10)
E. Hoist Removal and control box support (11) from
bracket assemblies (1 and 2).
(Ref. Figure 1)
(1). Remove power from aircraft (Ref. Detach support assemblies (9 and 10)
Section 96-00-00) from control box support assembly (11)
(2). Detach connectors P524, P525 and F. Skid Guard Removal

P526 from aircraft connectors J524, (Ref. Figure 3)
J525, and J536. (Ref CSP-900RMM-3,
98-30-00) (1). Remove fillet seal around all clamps (4).
Page 207
(2). Remove clamps (4) and guard (1). (1). Remove tie wraps as required and
G. Float Guard Removal remove straps (6).
(Ref. Figure 4). (2). Position and secure mating surfaces of
NOTE: This installation is only done when the Velcro (hook) (4) on cover (2) to velcro
aircraft is configured with both Rescue (pile) (5) area on float bag (2).
gether.
Page 208
SERVICING
1. Servicing Instructions NOTE: With the fairings installed, a flash light
and mirror are required to verify the fluid
A. Hoist Fluid Servicing level through the sight gauge.
(Ref. Figure 1). (1). Ensure fluid level is at or above
minimum level through the sight gauge
window.
(2). Add approved fluids as required
(Ref. Figure 1 and Table 1).
MINIMUM OIL LEVEL
OIL LEVEL
SIGHT GAUGE
9K25004A
Figure 1. Fluid Level Sight Gauge Location
Page 301
Table 1. Servicing Materials
SPECIFICATION MATERIAL MANUFACTURER

Hoist Assembly Oil
MILL7808 Staufer Jet I Stauffer Chemical Co.
380 Madison Avenue
New York, NY 10017
American PQ American Oil and
Lubricant 6899 Supply Co.
Mobil Avrex S Turbo 256 Mobil Oil Co.
Brayco 880H Bray Oil Co.
1925 Marianna Street
Los Angeles, CA 90032
Exxon Turbo Oil 2389 Exxon Co.
Page 302
RESCUE HOIST
INSPECTION / TEST
1. Rescue Hoist (9). Verify cable is lowered and CABLE
PAYOUT display registers correct
A. Hoist System Inspection reading.
(1). Inspect attaching components for A drag load of approximately 20
security of installation. CAUTION pounds must be applied to the
cable when hoisting to prevent cable from
(2). Inspect entire system for damage, becoming loose and fouling drum. Apply
deformations, cracks and excessive drag load with gloved hand or use a clean
wear. heavy cloth to protect hand and cable.
(3). Inspect cable and hoist assembly for (10). On collective control module, hold
condition. HOIST switch in UP position until
cable returns to original position.
(4). Inspect electrical connections for
Do not allow the payout of cable
condition and security of installation. CAUTION to be retarded. If cable is pre
(5). Replace any damaged or questionable vented from paying out, cable will loosen on
components. drum and foul drum. Cable tension rollers
are use to provide positive constant tension
B. Electrical System Functional Test between cable and drum.
(1). Apply external power to helicopter (Ref. (11). On pendant, lower cable using payout
CSP-900RMM-3, Section 96-00-00). direction/speed control thumbwheel
switch.
(2). On ELECTRICAL MASTER panel,
set POWER switch to BAT/EXT (12). Verify cable is lowered and cable payout
position. display on pendant registers correct
reading.
(3). On ELECTRICAL MASTER panel, A drag load of approximately 20
set R GEN switch to ON position. CAUTION pounds must be applied to the
(4). On electrical load center, verify HOIST cable when hoisting to prevent cable from
PWR and HOIST CUT circuit break becoming loose and fouling drum. Apply
ers are closed. drag load with gloved hand or use a clean
heavy cloth to protect hand and cable.
(5). On instrument panel, set HOIST (13). On pendant, raise cable using payout
switch to ON position. direction/speed control thumbwheel
(6). Verify hoist power on light is illumi switch to original position.
nated. (14). On pendant, set load mode select to
600 LB.
(7). On pendant, set load mode select to
250 LB. (15). Repeat steps (8). thru (13).
(16). On instrument panel, set HOIST
Do not allow the payout of cable
CAUTION to be retarded. If cable is pre switch to OFF position.
vented from paying out, cable will loosen on (17). On ELECTRICAL MASTER panel,
drum and foul drum. Cable tension rollers set R GEN switch to OFF position.
are use to provide positive constant tension (18). On ELECTRICAL MASTER panel,
between cable and drum. set POWER switch to OFF position.
(8). On collective control module, hold (19). Remove external power from helicopter
HOIST switch in DN position for a few (Ref. CSP-900RMM-3, Section
seconds. 96-00-00).

RESCUE HOIST SYSTEM

REPAIR
1. Repair Instructions
See Related Vendors Publications Hoist
Manufacturers Manual for repairs.
(Ref. 01-00-00 Table 202).

Section
257000
Hinged Avionics
Shelf
HINGED AVIONICS SHELF

1. Hinged Avionics Shelf 902 CONFIG hinged avionics shelf is identical
(Ref. Figure 1) to the 900 CONFIG shelf with the exception of
the -100 EEC mounting holes.
The hinged avionics shelves are located within
the ceiling area, above the baggage compart
ment. The left and right sides are typical. The
shelves hold their respective left and right side
Electronic Engine Control (EEC) units. When
required, the shelves can swing down from a
forward located hinge mechanism for mainte
nance and/or removal of the EEC's.
Page 1
25-70-00 Original
SHELF TEE LEFT SIDE SHOWN

RIGHT SIDE TYPICAL
AVIONICS CLIP
AFT OUTBOARD
BRACKET
SHELF CHANNEL
SHELF ASSEMBLY FWD OUTBOARD

BRACKET
SUPPORT ASSEMBLY
INTERCOSTAL
SHELF ANGLE
HINGE HALF
INTERCOSTAL HINGE HALF 9G25017
Figure 1. Hinged Avionics Shelf
Page 2
Original 25-70-00
HINGED AVIONICS SHELF

1. Hinged Avionics Shelf B. Avionics Shelf Channel Installation
A. Hinged Avionics Shelf Removal (Ref. Figure 201)
(Ref. Figure 201)
NOTE: Left and right sides are typical. CSP-SPM).
(1). Remove bolts (1) and washers (2) that (2). Install bolt (1), washer (2) and nut (3)
secure hinged avionics shelf (8) to securing avionics shelf channel (5) to
avionics shelf channel (5) and support upper avionics shelf tee (9). Torque nut.
assembly (6).
(2). Remove bolts (4), washers (2) and nuts (3). Install bolt (1) and washer (2) securing
(3) that secure shelf (8) to forward channel (5) to hinged avionics shelf (8).
hinge half (7). Torque bolt.
(3). Remove shelf (8). 3. Support Assembly

B. Hinged Avionics Shelf Installation
A. Support Assembly Removal
(Ref. Figure 201)
(Ref. Figure 201)
CSP-SPM). (1). Remove bolt (1) and washer (2) that
(2). Install bolts (4), washers (2) and nuts secure hinged avionics shelf (8) to
(3) securing shelf (8) to forward hinge support assembly (6).
half (7). Torque nuts.
(2). Remove bolts (1) and washers (2) that
(3). Install bolts (1) and washers (2) secure upper end of support assembly
securing shelf (8) to avionics shelf (6) to forward and aft outboard brack
channel (5) and support assembly (6). ets (10).
Torque bolts.
(3). Remove support assembly (6).
2. Avionics Shelf Channel
A. Avionics Shelf Channel Removal B. Support Assembly Installation

(1). Remove bolt (1) and washer (2) that (1). Install bolts (1) and washers (2)
secure hinged avionics shelf (8) to securing upper end of support assembly
avionics shelf channel (5). (6) to forward and aft outboard brack
(2). Remove bolt (1), washer (2) and nut (3) ets (10). Torque bolts.
that secure channel (5) to upper
avionics shelf tee (9). (2). Install bolt (1) and washer (2) securing
support assembly (6) to hinged avionics
(3). Remove channel (5). shelf (8). Torque bolt.
Page 201
25-70-00 Original
LEFT SIDE SHOWN

RIGHT SIDE TYPICAL
9
2 1
3 2
10
5 1
1
2
1 2
1 2
8 10
2
3
7 1
4
2
2
7 3 9G25011
Figure 201. Hinged Avionics Shelf
Page 202
Original 25-70-00

1. BOLT 6. SUPPORT ASSEMBLY
2. WASHER 7. HINGE HALF
3. NUT 8. HINGED AVIONICS SHELF
4. BOLT 9. UPPER AVIONICS SHELF TEE
5. AVIONICS SHELF CHANNEL 10. OUTBOARD BRACKET
4. Hinged Avionics Shelf gouges are allowed up to 0.006 inch

(0.152 mm). Corrosion spots up to
A. Hinged Avionics Shelf Inspection 0.010 inch (0.254 mm) in depth shall
(1). Inspect hinged avionics shelf for be removed and repaired (Ref. CSP-
security of installation. SPM).
(2). Inspect shelf and attaching brackets for (3). Verify that shelf assembly and avionics
cracks, corrosion or any other type of shelf channel meet electrical bonding
damage or deformation. Scratches or requirements (Ref. CSP-SPM).

25-70-00 Original
Chapter
FIRE PROTECTION
TABLE OF CONTENTS
26-10-10 Overheat Bleed Air Leak Detection (Heat/Defog) System . . . . . . . . . . A

1. Overheat Bleed Air Leak Detection (Heat/Defog) System . . . . . . . . . . . . . . . . . . . . . . 1
2. Overheat Bleed Air Leak Detection Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
A. Overheat Detection Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
B. Overheat Control Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Figure 1.Overheat Bleed Air Leak Detection (Heat/Defog) System . . . . . . . . . . . 2
Fault Isolation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
1. Overheat Bleed Air Leak Detection System Troubleshooting . . . . . . . . . . . . . . . . . . . 101
Table 101.Overheat Bleed Air Leak Detection (Heat/Defog) System
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Figure 101.Overheat Bleed Air Leak Detection System Wiring Diagram . . . . . 102
1. Overheat Bleed Air Leak Detection System Inspection/Test . . . . . . . . . . . . . . . . . . . . 201
A. Overheat Bleed Air Leak Detection System Inspection . . . . . . . . . . . . . . . . . . . . . . 201
B. Overheat Bleed Air Leak Detection System Cable Test . . . . . . . . . . . . . . . . . . . . . . 201
2. Overheat Bleed Air Leak Detection Cable (Heat/Defog) . . . . . . . . . . . . . . . . . . . . . . . 202
A. Overheat, Bleed Air Leak Detection Cable Removal . . . . . . . . . . . . . . . . . . . . . . . . 202
B. Overheat Bleed Air Leak Detection Cable Installation . . . . . . . . . . . . . . . . . . . . . . 202
Figure 201.Overheat Bleed Air Leak Detection Cable Installation
(Heat/Defog) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
3. Overheat Bleed Air Leak Detection Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
A. Overheat Bleed Air Leak Detection Control Removal . . . . . . . . . . . . . . . . . . . . . . . 204
B. Overheat Bleed Air Leak Detection Control Installation . . . . . . . . . . . . . . . . . . . . 204
Figure 202.Overheat Bleed Air Leak Detection Control . . . . . . . . . . . . . . . . . . . . . 204
26-10-20 Deck and Engine Area Fire/Overheat Detection System . . . . . . . . . . . A
1. Deck and Engine Area Fire/Overheat Detection System . . . . . . . . . . . . . . . . . . . . . . . 1
2. Deck and Engine Area Fire/Overheat Detection Components . . . . . . . . . . . . . . . . . . 1
A. Fire/Overheat Detection Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
B. Fire Control Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
C. Installation Brackets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Figure 1.Fire/Overheat Detection Cable, Deck and Engine Area . . . . . . . . . . . . . 2
Fault Isolation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
1. Deck and Engine Area Fire/Overheat Detection Troubleshooting . . . . . . . . . . . . . . . 101
Table 101.Deck and Engine Area Fire/Overheat Detection System
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Page i

Figure 101.Transmission Deck Fire/Overheat Detection System
Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
Figure 102.Engine Fire/Overheat Detection System Wiring Diagram . . . . . . . . 103
1. Deck and Engine Area Fire/Overheat Detection System Inspection/Test . . . . . . . . 201
A. Deck and Engine Fire/Overheat Detection Inspection . . . . . . . . . . . . . . . . . . . . . . . 201
B. Deck and Engine Fire/Overheat Detection Cable Test . . . . . . . . . . . . . . . . . . . . . . . 201
2. Deck Fire/Overheat Detection Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
A. Deck Fire/Overheat Detection Cable Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
B. Deck Fire/Overheat Detection Cable Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
Figure 201.Deck Fire/Overheat Detection Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
3. Engine Fire/Overheat Detection Cable (Typical) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
A. Engine Fire/Overheat Detection Cable Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
B. Engine Fire/Overheat Detection Cable Installation . . . . . . . . . . . . . . . . . . . . . . . . . 204
Figure 202.Engine Fire/Overheat Detection Cable (Typical) . . . . . . . . . . . . . . . . . 205
4. Deck and Engine Fire/Overheat Control (Typical) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
A. Fire/Overheat Control Unit Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
B. Fire/Overheat Control Unit Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
Figure 203.Deck and Engine Fire/Overheat Control Units . . . . . . . . . . . . . . . . . . 206
26-10-30 Smoke Detection System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A
1. Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
A. Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
B. Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
Figure 201.Smoke Detector System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
Figure 202.Smoke Detector Wiring Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
2. Smoke Detector Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
A. Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
B. Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
Figure 203.Smoke Detector Removal and Installation . . . . . . . . . . . . . . . . . . . . . . 203
3. Inspection and Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
26-20-10 Emergency Fire Extinguisher (Hand Held) . . . . . . . . . . . . . . . . . . . . . . . . A
1. Emergency Fire Extinguisher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
A. Emergency Fire Extinguisher Description and Operation . . . . . . . . . . . . . . . . . . . 201
B. Emergency Fire Extinguisher Fault Isolation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
Table 201.Emergency Fire Extinguisher System Troubleshooting . . . . . . . . . . . . 201
Page ii

C. Emergency Fire Extinguisher Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . . 201
D. Cabin Mounted Emergency Fire Extinguisher Removal/Installation
(Left/Right Sides Typical) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
E. Emergency Fire Extinguisher Inspection/Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
F. Emergency Fire Extinguisher Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
Figure 201.Emergency Fire Extinguisher (Hand Held) . . . . . . . . . . . . . . . . . . . . . 203
Figure 202.Cabin Mounted Emergency Fire Extinguisher,
Right Hand Shown (Left Hand Typical) . . . . . . . . . . . . . . . . . . . . . . . . . 204
26-20-20 Fire Extinguisher System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A
1. Fire Extinguisher System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Fire Extinguisher System Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
A. Fire Bottle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
B. Dual Valves/Outlet Ports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
C. System Tubing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
D. Pressure Gauges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
E. Filler Ports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Figure 1.Fire Extinguisher System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Fault Isolation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
1. Fire Extinguisher System Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Table 101.Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Figure 101.Fire Extinguisher System Wiring Diagram . . . . . . . . . . . . . . . . . . . . . 102
1. Fire Extinguisher System Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
Table 201.Minimum Serviceable Fire Bottle Pressure . . . . . . . . . . . . . . . . . . . . . . 201
2. Discharge Cartridge Bridgewire Resistances Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
Figure 201.Discharge Cartridge Bridgewire Resistance Test . . . . . . . . . . . . . . . . 202
3. Service Life Limit of Discharge Cartridges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
4. Fire Bottle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
A. Hydrostatic Testing Of Fire Bottle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
B. Weight Verification Of Fire Bottle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
5. Shipment of Fire Bottles and Discharge Cartridges . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
A. Shipment of Charged Fire Bottles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
B. Shipment of Discharge Cartridge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
6. Fire Bottle Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
A. Fire Bottle Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
B. Fire Bottle Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
Page iii

7. Fire Extinguisher Discharge Cartridge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
A. Discharge Cartridge Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
B. Discharge Cartridge Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
8. Discharge Tube Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
A. Discharge Tube Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
B. Discharge Tube Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
9. Distribution Tube Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
A. Distribution Tube Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
B. Distribution Tube Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
Figure 202.Fire Extinguisher System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
Page iv
Section
261010
Overheat Bleed Air
Leak Detection
(Heat/Defog) System
OVERHEAT BLEED AIR LEAK DETECTION

(HEAT/DEFOG) SYSTEM
1. Overheat Bleed Air Leak Detection The cable functions as a temperature averag
(Heat/Defog) System ing device, its absolute or base resistance
being a function of the surrounding ambient
(Ref. Figure 1) temperature. As the cable temperature rises
its resistance drops until it reaches a predeter
The overheat bleed air leak detection system mined set point of the control unit, at which
consists of an overheat detection cable routed point the warning (CAB HEAT) is displayed
around the length of the heat/defog bleed air on the Integrated Instrument Display System
line located under the right side cabin floor, (IIDS) panel.
and aft of the right side FS 230.5 bulkhead.
The cable is attached to a overheat control The use of a continuous loop enables the
unit located under the right side crew compart system to be monitored for open circuit
ment floor. condition. In the event of a single cable break,
the system remains operational. The connec
2. Overheat Bleed Air Leak Detection tors in the loop are ceramic cased or coated to
Components eliminate the possibility of a false alarm.
B. Overheat Control Unit
A. Overheat Detection Cable
The overheat control unit is a loop connector
The overheat detection cable is a single which detects the resistance drop in the
flexible semi-conductor type cable 0.070 detection cable and emits a signal to the IIDS
inches in diameter. The cable construction display. Two channels, fault, and overheat are
consist of one central conductor surrounded by interconnected and timed-phased in order to
a highly compacted layer of manganese oxide discriminate against false warnings resulting
semi-conductor material covered by a stain in a short in cable circuitry. In the event of an
less steel double outer sheath. It is the overheat bleed air leak condition the IIDS will
property of the semi-conductor that forms the shutoff the heat/defog system from the signal
basis of operation for the detection cable. received from the overheat control unit.
Page 1
26-10-10 Revision 4
OVERHEAT HEAT/DEFOG
CONTROL BLEED AIR LINE
OVERHEAT DETECTION
CABLE
DETECTION CABLE
RUBBER GROMMET
9G26001
Figure 1. Overheat Bleed Air Leak Detection (Heat/Defog) System
Page 2
Revision 4 26-10-10

(HEAT/DEFOG) SYSTEM
FAULT ISOLATION
1. Overheat Bleed Air Leak Detection Troubleshooting tables should be used with
System Troubleshooting system schematics, electrical wiring diagrams,
manual.
The following troubleshooting procedures are a
brief summary of overheat bleed air leak Comprehensive wiring diagrams are available
detection system faults which may be encoun in the Rotorcraft Maintenance Manual
tered (Ref. Table 101). CSP-900RMM-3.
Table 101. Overheat Bleed Air Leak Detection (Heat/Defog) System Troubleshooting
SENSFALT=12 Appears on Faulty overheat bleed air Remove and replace overheat 261000
IIDS alpha/numerical display. leak detection control box. control unit.
Fault in overheat Bleed air Circuit breaker BLD AIR Set or reset circuit breaker. 960000
leak detection (See Notes). LEAK CB 6 not set on
Electrical Load Center.
Faulty circuit breaker. Replace circuit breaker. 960000
Detector cable center Test detector cable. 261000
conductor high resistance.
Detector cable low insulation Test detector cable. 261020

resistance.
Faulty wiring between Test and repair wiring. 980000

overheat control unit and
IIDS.
NOTES:
(1) The overheat bleed air leak detection system is automatically self tested by the Integrated Instrument
Display System (IIDS) when electrical power is applied. Additionally if a manual test is required, a built in
fault detection circuit wired into a press to test DISP key located on the IIDS front panel may be used. By
depressing and holding the DISP key 3 to 5 seconds all liquid crystal display (LCD) illuminate. When the
DISP key is released a 1 second flash of the CAB HEAT WARNING indicates a normal functional
system. ACFTFALT=4 No flash of the CAB HEAT WARNING indicates a fault in the overheat bleed air
leak detection system.
Page 101
26-10-10 Revision 4
A669
BLEED AIR LEAK
DETECTOR CONTROL W309
FDL4
J1 P160 J478 P1
BLEED AIR LEAK
DETECTION CABLE
LOOP A D A
A612
J161 P2 LOOP FWD INTERCONNECT PANEL
A2
W122
LOOP B H B IIDS
P172 J6 TB3-8 J3 P170 P105 J5
W124
TEST K 63 A B C D 76 ZN DETECTOR TEST
25K .25W
EXTERNAL CALIBRATION RTN B
R1 J3
CALIBRATION RESISTOR E P103
BLEED AIR LEAK DETECT C 64 77 57 LEAK DETECT

FAULT F 65 78 63 DETECTOR
LEAK
FAULT
CHASSIS GND A E
PWR GND J E
28VDC PWR G
A601 900 CONFIG A601 902 CONFIG

W124
CB36 J2 P128
CB6 J2 P128 BLD AIR LEAK
BLD AIR LEAK
L. ESS BUS 14
5A
28VDC 14
5A
9G26011B
Figure 101. Overheat Bleed Air Leak Detection System Wiring Diagram
Page 102
Revision 4 26-10-10

(HEAT/DEFOG) SYSTEM
1. Overheat Bleed Air Leak Detection (12). Install soft insulation interior trim
System Inspection/Test panel on aft right side of FS 230.5
bulkhead (Ref. Section 25-50-00).
A. Overheat Bleed Air Leak Detection
System Inspection (13). Install cabin floor panel AR165 (Ref.
Section 06-00-00).
(Ref. Figure 201)
(14). Install cockpit floor access panel AR138
(1). Remove soft insulation panel on aft and AR129 (Ref. Section 06-00-00).
right side of FS 230.5 bulkhead (Ref.
25-50-00). B. Overheat Bleed Air Leak Detection
System Cable Test
(2). Remove cockpit floor access panels
AR129 and AR138 (Ref. Section Special Tools
06-00-00). (Ref. CSPSPM)
Item Nomenclature
(3). Remove cabin floor panel AR165 (Ref.
T1002 MilliOhm Meter
Section 06-00-00).
T1012 Megohmmeter, Digital/Analog
(4). Remove right baggage compartment
outboard floor panel AR250 (Ref.
Section 06-00-00). (1). Detach connectors at both ends of cable.
(2). Verify the cable contact pin is centered

(5). Inspect detection cable for broken wire.
in the connector. No physical damage
Replace cable assembly if broken.
allowed.
(6). Inspect sensor portion of cable for (3). Inspect for corrosion or foreign objects.
chafing. 0.006 in (0.152 mm) maximum None allowed.
depth allowed.
(4). Using milli-ohm meter (T1002)
(7). Inspect cable tie straps securing cable measure the resistance from the center
to bleed air line and to inside and pin on one end to the center pin on the
outside shields. Replace broken ties. other end. Maximum resistance 8.05
ohm.
(8). Inspect rubber grommet securing
detection cable for deterioration. (5). Using megohmmeter (T1012) measure
Replace grommets as required. the resistance from the center pin to
the outer sheath (center pin negative).
(9). Inspect control unit for security of
attachment hardware. Electrical Use 100 Vdc test voltage.
connector for corrosion and security.
Test at ambient temperature of 70 F
(21.1 C) to 80 F (26.7 C).
(10). Inspect connector couplings for safety
wire and security. Minimum resistance 1.7 Mohm.
(11). Install right baggage compartment (6). Replace faulty cable.
outboard floor panel AR250 (Ref.
Section 06-00-00). (7). Attach connectors at both ends of cable
Page 201
26-10-10 Revision 4
2. Overheat Bleed Air Leak Detection Cable B. Overheat Bleed Air Leak Detection Cable
(Heat/Defog) Installation
(Ref. Figure 201) Do not exceed minimum bend
CAUTION radius 0.750 inch (19.05 mm).
Consumable Materials (1). Install detection cable from baggage
(Ref. CSPSPM) compartment through FS 230.5
Item Nomenclature bulkhead and holes in each structure to
C701 Lockwire
FS 155.5 bulkhead.
NOTE: Cable does not need to be in contact
with bleed air line.
A. Overheat, Bleed Air Leak Detection Cable
Removal (2). Wrap detection cable 3 turns around
horizontal length of bleed air line.
(1). Remove right crew seat from cockpit
(Ref. Section 25-10-00). (3). Wrap cable 31/2 turns around vertical
length of bleed air line.
(2). Remove cabin seats from cabin
compartment if applicable (Ref. Section (4). Install mounting nuts on cable ends
25-20-00). and torque nuts. Safety nuts with
lockwire (C701).
(3). Remove interior trim and insulation
(5). Install rubber grommets along cable.
panels from aft right side FS 230.5
Secure cable to bleed air line with
bulkhead (Ref. Section 25-50-00).
tiedown straps at grommets.
(4). Remove carpet from cabin floor panels, (6). Attach electrical connector P1 to
if applicable (Ref. Section 25-20-00). forward cable end connection. Torque
connector. and safety with lockwire
(5). Remove cockpit access panels AR129
(C701).
and AR138 (Ref. Section 06-00-00).
(7). Attach electrical connector P2 to aft
(6). Remove cabin floor panels; A160, cable end connection. Torque connector
AR165, AL165, A170, and A217(Ref. and safety with lockwire (C701).
Section 06-00-00).
(8). Install baggage compartment floor
(7). Remove baggage floor panels A235 and panels AR250 and A235 (Ref. Section
AR250 (Ref. Section 06-00-00). 06-00-00).
(8). Detach electrical connector P1 (1) from (9). Install cabin floor panels A160, AR165,
forward bleed air leak detection cable AL165, A170, and A217 (Ref. Section
(5) end connection. 06-00-00).
(9). Detach electrical connector P2 (2) from (10). Install cockpit floor panels AR129 and
aft cable end connection. AR138 (Ref. Section 06-00-00).
(10). Cut and discard lockwire and remove (11). Install carpet in cabin, if applicable (Ref
mounting nuts (6) from cable ends. Section 25-20-00).
Remove cable ends from bulkheads. (12). Install insulation and interior trim
panels on aft right side FS 230.5
(11). Cut and discard tie down straps (8) bulkhead (Ref. Section 25-50-00).
securing cable to bleed air line.
(13). Install cabin seats in cabin compart
(12). Remove and retain rubber grommets ment, if applicable (Ref. Section
(7) from fire detection cable. 25-10-00).
(13). Carefully unwrap fire detection cable (14). Install right crew seat in cockpit (Ref.
from bleed air line and remove cable. Section 25-10-00).
Page 202
Revision 4 26-10-10
5.43
(13.79 cm)
43.43
(110.3 cm)
9
3
70-80 in-lb
7.9-9.0 Nm
6 4
65-75 in-lb
7.3-8.5 Nm
2
1
65-75 in-lb 5
LOOKING
7.3-8.5 Nm
FORWARD
6
8 7 70-80 in-lb
7.9-9.0 Nm 5.06
(12.85 cm)
5 9
1.33
11.46 (3.38 cm)
(29.11 cm) 2.42
8.58 (6.15 cm) 9.38
(21.79 cm) 11.86 35.60 17.63 (23.83 cm)
(30.12 cm) (90.42 cm) (44.78 cm)
LOOKING OUTBOARD
RIGHT SIDE
9G26013
1. ELECTRICAL CONNECTOR (P1) 6. MOUNTING NUT

2. ELECTRICAL CONNECTOR (P2) 7. RUBBER GROMMET
3. ELECTRICAL CONNECTOR (P160) 8. TIEDOWN STRAP
4. OVERHEAT BLEED AIR LEAK CONTROL UNIT 9. HEAT/DEFOG BLEED AIR LINES
5. OVERHEAT BLEED AIR LEAK DETECTION CABLE
Figure 201. Overheat Bleed Air Leak Detection Cable Installation (Heat/Defog)
Page 203
26-10-10 Revision 4
3. Overheat Bleed Air Leak Detection (4). Install cockpit floor panels AR138 and
Control AR129 (Ref. Section 06-00-00).
(Ref. Figure 202) (5). Install right crew seat in cockpit (Ref.
Section 25-10-00).
A. Overheat Bleed Air Leak Detection
Control Removal STA. 155.0 BKHD
3 2 1 (4 PL) 4 (4 PL)
(1). Remove right crew seat in cockpit (Ref.
Section 25-10-00).
(2). Remove cockpit floor panels AR129 and
AR138 (Ref. Section 06-00-00).
(3). Detach electrical connector P160 (3)
from bleed air leak detection control (2).
(4). Remove screws (1) from bleed air leak
detection control and spacers (4) and
remove control from bulkhead.
B. Overheat Bleed Air Leak Detection
Control Installation
CSP-SPM).
9G26002
(2). Install bleed air leak detection control 1. SCREW
onto bulkhead with spacers and screws. 2. BLEED AIR LEAK DETECTION CONTROL
3. ELECTRICAL CONNECTOR (P160)
Torque screws. 4. SPACER
(3). Attach electrical connector P160 to Figure 202. Overheat Bleed Air Leak
bleed air leak detection control. Detection Control
Page 204
Revision 4 26-10-10
Section
261020
Deck and Engine
Area Fire/Overheat
Detection System
DECK AND ENGINE AREA FIRE/OVERHEAT DETECTION SYSTEM

1. Deck and Engine Area Fire/Overheat coated to eliminate the possibility of false
Detection System alarm due to a bridging action of conducting
materials. The use of a continuous loop
(Ref. Figure 1) enables the system to be monitored for open
circuit condition. In the event of a single cable
The fire/overheat detection for the transmis
sion deck and engines consist of detection break, the system remains operational.
cables, control units, and installation brackets. The cable is a temperature averaging device,
The upper deck detection cable is routed down its absolute or base resistance being a function
the front center panel of the firewall assembly, of the surrounding ambient temperature. As
under each engine accessory assembly, and the cable temperature rises, its resistance
around the upper deck under the edge of the drops until it reaches the predetermined set
transmission. point of the control unit.
The engine detection cables are routed on the B. Fire Control Unit
engine compartment inboard firewall and
inboard half of the aft firewall. Each detection The fire control units are solid state assem
cable is connected to a separate fire control blies. When the average temperature rises, the
unit located on the aft cabin compartment control unit will sense the drop in resistance
bulkhead. until it reaches the set point and sends a
signal to the Integrated Instrument Display
2. Deck and Engine Area Fire/Overheat System (IIDS) displaying a fire warning
Detection Components (FIRE).
A. Fire/Overheat Detection Cable Two channel discriminators, fault and fire, are
interconnected and time-phased in order to
The fire/overheat detection cable is a 0.070 discriminate against false fire warnings
inch (1.778 mm) outside diameter, double wall, resulting in a short in cable circuitry. Resis
flexible stainless steel tube. The tube contains tance used in the system is 75 ohms, short
a single wire center conductor in a highly discriminator actuating resistance is 60 ohms.
compacted manganese oxide semi-conductor These values assure ample margin between
material. fire alarm resistance and short circuit resis
tance.
A double steel sheath is used for the cable to
be stronger and more flexible. The cable can C. Installation Brackets
bend to a minimum installation radius of
0.750 inch (19.1 mm). Standoff brackets, stainless steel positive
locking cable clamps, and high temperature
All metal surfaces within the systems electri silicon rubber grommets are used for installa
cal connectors are ceramic coated or surface tion of the detection cables.
Page 1
26-10-20 Revision 4
FIRE DETECTION CABLE

RIGHT ENGINE

LEFT ENGINE
FIRE DETECTOR FIRE DETECTION CABLE

CONTROL UNITS INTERCONNECTS LEFT ENGINE
TOP-TO-RIGHT ENGINE
MIDDLE-TO-DECK ab
BOTTOM-TO-LEFT ENGINE 9G26006
DECK FIRE
DETECTION CABLE
Figure 1. Fire/Overheat Detection Cable, Deck and Engine Area
Page 2
Original 26-10-20

FAULT ISOLATION
1. Deck and Engine Area Fire/Overheat Troubleshooting tables should be used with
Detection Troubleshooting system schematics, electrical wiring diagrams,
(Ref. Figure 101 and Figure 102) procedures in this and other chapters of the
manual.
brief summary of deck and engine area Comprehensive wiring diagrams are available
fire/overheat detection system faults which in the Rotorcraft Maintenance Manual
may be encountered (Ref. Table 101). CSP-900RMM-3.
Table 101. Deck and Engine Area Fire/Overheat Detection System Troubleshooting
Fault in fire/overheat Circuit breaker XMSN F/D Set or reset circuit breaker. 960000
detection system. (See (CB 3) not set.
Notes)
Circuit breaker L ENG F/D Set or reset circuit breaker. 960000
(CB 4) not set.
Circuit breaker R ENG F/D Set or reset circuit breaker. 960000
(CB 5) not set.
Faulty wiring between: Test and repair wiring. 980000
fire/overheat detection
control unit and IIDS.
Detector cable center Test detector cable. 261020
conductor high resistance.
Detector cable low insulation Test detector cable. 261020
resistance.
Faulty fire/overheat Remove and replace 261020
detection control unit. fire/overheat detection control
unit.
Page 101
26-10-20 Revision 4
Table 101. Deck and Engine Area Fire/Overheat Detection System Troubleshooting (Cont.)
SENSFALT=12 On IIDS Faulty fire/overheat Remove and replace 261020
alpha/numerical display. (See detection control unit. fire/overheat detection control
Notes) unit
NOTES:
(1) The Fire/overheat detection system is automatically self tested by the Integrated Instrument Display
System (IIDS) when electrical power is applied. Additionally if a manual test is required, a built in fault
detection circuit wired into a press to test DISP key located on the IIDS front panel may be used. By
depressing and holding the DISP key 3 to 5 seconds all liquid crystal display (LCD) illuminate. When the
DISP key is released a 1 second flash from each (FIRE) WARNING indicator indicates a normal
functional system. No flash of (FIRE) WARNING indicates a fault in the system that failed to flash. Each
is connected to a separate fire control unit circuit test through the IIDS.
ACFTFALT = 1 Transmission fire detect fault, ACFTFALT =2 Left engine fire fault, or
ACFTFALT =3 Right engine fire fault will appear on IIDS fault log alpha/numerical display for the failed
detection system.
A2 A602
IIDS
W123 W124
J2 P102 P377 J3 J2 P374
T T T T T
XMSN FIRE 58 M 14
XMSN FIRE FAULT 59 N 15
XMSN TEST 60 P 16
A105
A601 902 CONFIG FIRE/OVERHEAT
CIRCUIT BREAKER PANEL CONTROL
A601 900 CONFIG
CB4 (TRANSMISSION DECK)
XMS J2 P128
BAT 5A N CB3 W124
2 P370 J1
BUS FIRE XMSN FIRE T
L. ESS BUS
J2 P128 C FIRE
FDL1 BAT 5A 2 F FAULT
FIRE DETECTION CABLE BUS K TEST
(TRANSMISSION DECK)
P2 J475 W124 G 28VDC
LOOP B H LOOP B
GS304-F E A CHASSIS GROUND
P1 J477
GS306-K E J PWR GND
A D LOOP A
B EXTERNAL CALIBRATION
RTN
E CALIBRATION RESISTOR
9G26009B
Figure 101. Transmission Deck Fire/Overheat Detection System Wiring Diagram
Page 102
Original 26-10-20
A103
A2 A602 FIRE/OVERHEAT
IIDS CONTROL (LH ENGINE)
W122 W124
P376 J4 J2 P374 P371 J1
J3 P103
T T T T T T
L ENG FIRE 64 C 8 C FIRE
L ENG FIRE FAULT 65 E 9 F FAULT
L ENG TEST 66 P 10 K TEST
G 28VDC
W123 GS302-B
J2 P102 P377 J3
T T T T E A CHASSIS GROUND
T
R ENG FIRE 64 9 11 B EXTERNAL CALIBRATION RTN
R ENG FIRE FAULT 65 10 12 E CALIBRATION RESISTOR
R ENG TEST 66 11 13 E J PWR GND
GS304-E
D LOOP A
P375 J1
H LOOP B
A601 900 CONFIG 17
26
CIRCUIT BREAKER PANEL W125
FDL3
A102
CB4 FIRE/OVERHEAT
L. ENG FIRE (LH ENGINE)
P379 J5 J6 P376 W124 CONTROL (RH ENGINE)
P2 J473
J1 P131
A H E P372 J1
5A 1 T
C FIRE
LOOP
P1 J479 F FAULT
BAT BUS K TEST
B J M
GS302-D E A CHASSIS GROUND
CB5 GS306-H E J PWR GND
R. ENG FIRE B EXTERNAL CALIBRATION RTN
J2 P128 W124
E CALIBRATION RESISTOR
5A 1 G 28VDC
FDL2 D LOOP A
FIRE DETECTION CABLE H LOOP B
(RH ENGINE) P1 J476 W124
A601 902 CONFIG
A
CB21 LOOP P2 J474
L. ENG FIRE
J1 P131 B
5A 1
CB3
R. ENG FIRE
J2 P128
5A 1
L. ESS BUS
9G26010B
Figure 102. Engine Fire/Overheat Detection System Wiring Diagram

26-10-20 Original

1. Deck and Engine Area Fire/Overheat B. Deck and Engine Fire/Overheat Detection
Detection System Inspection/Test Cable Test
(Ref. Figure 201, Figure 202, and Figure 203) Special Tools
(Ref. CSPSPM)
A. Deck and Engine Fire/Overheat Detection Item Nomenclature
Inspection
T1012 Megohmmeter, Digital/Analog
(1). Remove engine cowl assembly L260 or
R260 (Ref. Section 06-00-00).
(1). Detach connectors at both ends of cable.
(2). Inspect fire detection control units for
security. (2). Verify the cable contact pin is centered
in the connector. No physical damage
(3). Inspect fire detection cable connectors allowed.
for security. (3). Inspect for corrosion or foreign objects.
None allowed.
(4). Inspect sensor portion of cable for
chafing. 0.006 in (0.152 mm) maximum (4). Using milli-ohm meter (T1002)
depth allowed. measure the resistance from the center
pin on one end to the center pin on the
(5). Inspect fire detection cable for breaks. other end.
Replace cable assembly if broken. Maximum resistance 4.25 ohm for
engine detection cable.
(6). Inspect quick release clamps for
security, quick release mechanism for Maximum resistance 8.05 ohm for
latching and locking. Repair or replace transmission detection cable.
as required. (5). Using megohmmeter (T1012) measure
the resistance from the center pin to
(7). Inspect for damaged or broken Z the outer sheath (center pin negative).
brackets. Repair or replace as required.
Use 100 Vdc test voltage.
(8). Inspect detection cable for missing, Test at ambient temperature of 70 F
deteriorated, and secure rubber (21.1 C) to 80 F (26.7 C).
grommets. Repair of replace as re
quired. Minimum resistance 1.7 Mohm.
(6). Replace faulty cable.
(9). Install engine cowling assembly L260
or R260 (Ref. Section 06-00-00). (7). Attach connectors at both ends of cable
Page 201
26-10-20 Revision 4
2. Deck Fire/Overheat Detection Cable B. Deck Fire/Overheat Detection Cable

Installation
(Ref. Figure 201)
NOTE: Replace any unserviceable Z brackets,
grommets, or quick release clamps. Apply
Consumable Materials sealing compound (C205) to faying surface
(Ref. CSPSPM) of replaced Z brackets.
Item Nomenclature
C701 Lockwire
A. Deck Fire/Overheat Detection Cable (1). Replace unserviceable Z brackets.

Removal
(2). Install replacement quick release
(1). Remove L210 and R210 transmission clamps using screws, washers, and
access doors (Ref. Section 06-00-00). nuts. Torque nuts.
Do not exceed minimum bend
(2). Remove aft swashplate fairing assem CAUTION radius 0.750 inch (19.05 mm).
bly T220 (Ref. Section 06-00-00).
(3). Form fire detection cable to fit original
(3). Cut and discard lockwire and detach mounting locations.
electrical connectors J475 (8) and J477
(9) from fire detection cable (1). (4). Place grommets on cable at each quick
release clamp.
(4). Disconnect fire detection cable quick (5). Secure fire detector cable, with grom
release clamps (2). met, in quick release clamp.
(5). Careful remove fire detection cable (6). Attach electrical connector J475 and
from upper deck. J477 to fire detection cable connectors.
Torque connectors and safety with
(6). Remove and retain rubber grommets lockwire (C701).
(3) from cable. (7). Install aft swashplate fairing assembly
T220 (Ref. Section 06-00-00).
(7). Remove unserviceable quick release
clamps. Remove screws (4), washers (5), (8). Install L210 and R210 transmission
and nuts (6). access doors (Ref. Section 06-00-00).
Page 202
Revision 4 26-10-20
4
70 -90 in-lb 2
65 -75 in-lb 10 10 5
8 7.9 - 10.2 Nm
7.3 - 8.5 Nm
3
65 -75 in-lb
9
7.3 - 8.5 Nm 11
10 10 12
7
6
9G26004A
1. DECK FIRE/OVERHEAT DETECTION CABLE 7. Z BRACKET
2. QUICK RELEASE CLAMP 8. ELECTRICAL CONNECTOR (J475)
3. RUBBER FIRE DETECTOR GROMMET 9. ELECTRICAL CONNECTOR (J477)
4. SCREW 10. CONNECTOR MOUNTING NUTS
5. WASHER 11. ELECTRICAL CONNECTOR (J475 FDL P2)
6. NUT 12. ELECTRICAL CONNECTOR (J477 FDL P1)
Figure 201. Deck Fire/Overheat Detection Cable
Page 203
26-10-20 Original
3. Engine Fire/Overheat Detection Cable B. Engine Fire/Overheat Detection Cable

(Typical) Installation
Do not exceed minimum bend
(Ref. Figure 202) CAUTION radius 0.750 inch (19.05 mm).
Consumable Materials (1). Form fire detection cable to fit original

(Ref. CSPSPM) mounting locations.
Item Nomenclature NOTE: Replace unserviceable grommets and
C701 Lockwire quick release clamps.
C215 Sealing Compound, Fireproof (2). Install replacement quick release
clamps using screws, washers, and
nuts. Torque nuts.
A. Engine Fire/Overheat Detection Cable
Removal (3). Place grommets on cable at quick
release clamp.
(1). Open engine cowling assembly L260 or
R260 (Ref. Section 06-00-00). (4). Secure fire detector cable with grommet
in quick release clamp.
(2). Cut and discard lockwire and detach (5). Attach electrical connectors to fire
electrical connectors J474 (1) and J476 detection cable connectors J474 and
(2) for right engine or J473 (4) and J476 right engine or J473 and J479 left
J479 (5) for left engine fire detection engine. Torque connectors and safety
cable (3). with lockwire (C701).
(3). Disconnect quick release clamps (11). Sealing Compound (C215)
(4). Careful remove fire detection cable

from firewall.
(5). Remove and retain grommets (12) from (6). Apply fillet of sealing compound (C215)
cable. to cable mounting nuts on engine side
of firewall.
(6). Remove unserviceable quick release
clamps, remove screws (7), washers (8), (7). Install engine cowling assembly L260
and nuts (9). or R260 (Ref. Section 06-00-00).
Page 204
Revision 4 26-10-20
70 -90 in-lb
65 -75 in-lb 1 6 6 7.9 - 10.2 Nm
7.3 - 8.5 Nm 4
J473 J474 J373 J374
LEFT RIGHT LEFT RIGHT
65 -75 in-lb 2
7.3 - 8.5 Nm 5
7 J479 J476 J379 J376
LEFT RIGHT LEFT RIGHT
8 11
12
3
10 6 6
9 13
9G26016A
1. ELECTRICAL CONNECTOR (RIGHT ENGINE J474) 8. WASHER
2. ELECTRICAL CONNECTOR (RIGHT ENGINE J476) 9. NUT
3. RIGHT ENGINE DETECTION CABLE 10. LEFT ENGINE DETECTION CABLE
4. ELECTRICAL CONNECTOR (LEFT ENGINE J473) 11. QUICK RELEASE CLAMP
5. ELECTRICAL CONNECTOR (LEFT ENGINE J479) 12. FIRE DETECTOR RUBBER GROMMET
6. MOUNTING NUT 13. ZBRACKET
7. SCREW
Figure 202. Engine Fire/Overheat Detection Cable (Typical)
Page 205
26-10-20 Revision 4
4. Deck and Engine Fire/Overheat Control (4). Remove screws (5) and washers (6), and
(Typical) remove control from bracket assembly
(4).
(Ref. Figure 203) B. Fire/Overheat Control Unit Installation
A. Fire/Overheat Control Unit Removal (1). Install control on bracket assembly

with screws and washers. Torque
screws.
(1). Remove right aft cabin passenger seat,
if installed (Ref. Section 25-20-00). (2). Attach electrical connector transmis
sion deck P370, left engine P371, or
(2). Remove right aft cabin interior trim right engine P372 to fire/overheat
panel (Ref Section 25-20-00). control.
(3). Install right aft cabin interior trim
(3). Detach electrical connector transmis panel (Ref Section 25-20-00).
sion deck P370 (2), left engine P371 (3),
or right engine P372 (1), from fire/over (4). Install right aft cabin passenger seat
heat control unit. (Ref. Section 25-20-00).
4
NOTE: THE UPPER DECK AND ENGINES FIRE/OVERHEAT DETECTION CIRCUITS 5
ARE CONNECTOR DEPENDANT AND ARE NOT CONTROL UNIT INDEPENDENT 6
9G26003A
1. RIGHT ENGINE FIRE/OVERHEAT CONTROL (P372) 4. MOUNTING BRACKET ASSEMBLY
2. TRANS. DECK FIRE/OVERHEAT CONTROL (P370) 5. SCREW
3. LEFT ENGINE FIRE/OVERHEAT CONTROL (P371) 6. WASHER
Figure 203. Deck and Engine Fire/Overheat Control Units
Page 206
Revision 4 26-10-20
Section
261030
Smoke Detection
System
SMOKE DETECTION SYSTEM

1. Description and Operation Panel (4) thru the A675 Audio Intercon
Assembly (5).
A. Description
(Ref. Figure 201) B. Operation
The optional smoke detection system has a (Ref. Figure 202)

smoke detector (1) installed in the baggage
compartment with a wiring harness (2) that Refer to the wiring diagram and the applicable
connects the detector to the A620 Electrical Rotorcraft Flight Manual (RFM) for operation
Load Center (3) and the A652 Audio Select of the smoke detection system.
5 1
4 9g26-022
1. SMOKE DETECTOR (REF. IPL, 261030, FIG. 1) 4. A652 AUDIO SELECT PANEL (REF. IPL, 970000, FIG.
2. WIRING HARNESS (NOT SHOWN) 1)
3. A620 ELECTRICAL LOAD CENTER (REF. IPL, 5. A675 AUDIO INTERCON ASSEMBLY
960001, FIG. 1)
Figure 201. Smoke Detector System
Page 201
A804
SMOKE DETECTOR
J1 P852
28VDC INPUT PWR A W44B22 EMI 3
TEST INPUT (GND) C W45A22 EMI 3

ALERT RELAY (N.O.) E W46A22 EMI 3
NO CONNECTION F W49A22 EMI 3
P852
SP1
CHASSIS GND D W47A22 EMI 3 E GS302-K
DC GND B W48A22 EMI 3 E GS304-G
A620
ELEC LOAD CENTER
SMOKE DETECTOR FIRE HRD
P378 J4 CB31 CB32
W44B22 EMI 3 (B) W44A22 EMI 3 W50A22 EMI 3 BAT

5A 5A BUS
W45A22 EMI 3 (C)
W45B22 EMI 3 W45C22N EMI 3 E E1

SMOKE TEST
A675
AUDIO INTCON ASSY
S
A652
AUDIO SELECT PANEL
R
P 20-21-050 P501 J1
N 11 ALERT #1
W49B22 EMI 3
9G26-020
Figure 202. Smoke Detector Wiring Schematic
2. Smoke Detector Removal and Installation (2). Remove nuts (5) and washers (4) from
(Ref. Figure 203) studs (3).
A. Removal
(1). Disconnect Electrical Connector P852. (3). Remove smoke detector (2).
Page 202
B. Installation (2). Torque nuts (5) sufficiently to prevent

the axial movement of smoke detector
(2).
(1). Install smoke detector (2) on studs (3)
with washers (4) and nuts (5). (3). Connect Electrical Connector P852.
.250 .280 THRU
P852
5
3
4
BAGGAGE COMPARTMENT
DOOR OPENING
9G26-021
1. WIRING HARNESS (REF. IPL, 261030, FIG. 1) 4. WASHER

2. SMOKE DETECTOR 5. NUT
3. STUD
Figure 203. Smoke Detector Removal And Installation
Page 203
3. Inspection and Test

Refer to the applicable RFM to do a test of the
smoke detector system.
Page 204
Section
262010
Emergency Fire
Extinguisher
(Hand Held)
EMERGENCY FIRE EXTINGUISHER (HAND HELD)

1. Emergency Fire Extinguisher The helicopter has the option of being
equipped with a disposable hand held fire
A. Emergency Fire Extinguisher Description extinguisher that can be mounted on either
and Operation the left or right hand side of the cabin. This
extinguisher has no gauge, and discharges 14
The helicopter is equipped with a hand held oz of a unique blend of Halon 1211-1301
(26 oz) fire extinguisher that mounts on the aft extinguishing agent (Ref. Section 01-00-00).
side of the center console. The extinguisher
uses a liquified gas which discharges Halon B. Emergency Fire Extinguisher Fault
1211 extinguishing agent as a vapor at high Isolation
nozzle velocity. A pressure gage on the
extinguisher indicates charge, normal, and The following troubleshooting procedures are a
overcharge pressures. Green area indicates brief summary of emergency fire extinguisher
normal operating range of 125 psi. Red area system faults which may be encountered (Ref.
indicates CHARGE or OVERCHARGE. Table 201).
Table 201. Emergency Fire Extinguisher System Troubleshooting

Fire extinguisher displays Prolonged exposure to Replace bottle. 262010
excessive damage, harsh elements.
corrosion or pitting.
Gross weight is below Excessive leakage around Replace bottle. 262010
manufacturers recom- the valve and O rings.
mendations.
Previously discharged. Replace bottle (14 oz). 262010
Service (26 oz) fire 262010
extinguisher in accor-
dance with manufacturers
instructions.
Pressure gauge (26 oz) Overcharged or Service (26 oz) fire 262010
indicates red. discharged extinguisher in accor-
dance with manufacturers
instructions.
Mounting brackets Heavy cargo or equipment Repair or replace as 262010
damaged or release latch making contact. required.
damaged and working
improperly.
C. Emergency Fire Extinguisher (2). Remove screws (3), washers (4) and
Removal/Installation bracket (2).
(Ref. Figure 201) (3). Install bracket (2) with screws (3) and
washers (4).
(1). Unfasten clasps on the fire extinguisher
bracket (2) and remove fire extinguish (4). Hang extinguisher (1) on bracket (2)
er (1). and secure with clasps.
Page 201
D. Cabin Mounted Emergency Fire E. Emergency Fire Extinguisher

Extinguisher Removal/Installation Inspection/Check
(Left/Right Sides Typical)
NOTE: The cabin mounted fire extinguisher
(Ref. Figure 202) does not require a six year maintenance, hy
drostatic testing, or recharging. Refer to
name plate on extinguisher for further de
Consumable Materials tails.
(Ref. CSPSPM)
Item Nomenclature (1). Examine fire extinguisher for signs of
C301 Epoxy Primer damage, corrosion, pitting or other
conditions which could prevent opera
C411 Epoxy Adhesive
tion.
(2). Visually inspect nozzle to insure no
(1). Unfasten clasp on the fire extinguisher obstructions exists.
bracket (2) and remove fire extinguish
er (3). (3). Verify pressure gauge indication on (26
oz) fire extinguisher and date of last
(2). Remove screws (7), and bracket (2). servicing.
(3). Remove self-locking nuts (6), washers (4). Determine fullness of fire extinguisher
(5), and cabin mounted brackets (1) by weighing. Compare to manufactur
from bonded studs (4). er's recommended gross weight listed
on extinguisher name plate.
NOTE: When replacing unserviceable studs (4),
apply epoxy adhesive (C411) to faying sur (5). Service (26 oz) fire extinguisher in
faces of new studs (4). accordance with manufacturers
instructions.
(6). Examine fire extinguisher bracket for
proper installation and damage. Insure
clasp opens easily and locks correctly.
(7). Examine mounting brackets (cabin
(4). Check for unserviceable studs (4), and mounted) for proper installation and
replace as required. damage.
(5). Install brackets (1), nuts (6) and F. Emergency Fire Extinguisher Operation
washers (5).
Fire Extinguisher
Primer, Epoxy (C301)
Fire Extinguisher Fluid

(6). Apply epoxy primer (C301) on bracket
(1) mounting hardware (Ref. CSP-
SPM, 20-30-00, Application of Epoxy
Primer).
(1). Grasp fire extinguisher handle with one
Upon assembly, confirm screws hand. Use the thumb and forefinger of
CAUTION (7) do not contact fuselage. the other hand to unfasten the clasp.
Remove fire extinguisher from bracket.
(7). Install using bracket (2) and screws (7). Remove safety pin from handle.
(8). Hang extinguisher (3) on bracket (2) (2). Point nozzle toward base of flame and
and secure with clasp. squeeze the handle.
Page 202
4
3
9G26-017
Figure 201. Emergency Fire Extinguisher (Hand Held)

1. 26 OZ FIRE EXTINGUISHER 3. SCREW
2. FIRE EXTINGUISHER BRACKET 4. WASHER
Page 203
3 4
4
7
5
5
6
7 5
9G26-019
Figure 202. Cabin Mounted Emergency Fire Extinguisher, Right Hand Shown (Left Hand
Typical)
1. CABIN MOUNTED BRACKET 5. WASHER
2. FIRE EXTINGUISHER BRACKET 6. SELFLOCKING NUT
3. 14 OZ FIRE EXTINGUISHER 7. SCREW
4. BONDED STUD
Page 204
Section
262020
Fire Extinguisher
System
FIRE EXTINGUISHER SYSTEM

1. Fire Extinguisher System C. System Tubing
The fire extinguisher system consists of two Discharge tubes flow extinguishing agent from
fire bottle assemblies, discharge tubes, the primary valve/outlet port (red) to the
distribution tubes, cross flow tubes, wiring engine deck through fitting. Distribution tubes
harness, and mounting brackets. flow extinguishing agent and incorporate two
openings each for emitting the agent.
Each fire bottle is equipped with dual valve/
outlet ports with discharge cartridges, a The cross flow tubes are connected to the
pressure gauge with an electrical low pressure alternate valve/outlet port (blue). Cross flow
warning sensor, filler port, and thermal relief tubes flow extinguishing agent to the opposite
valve. side discharge tube for fire extinguisher
redundancy.
2. Fire Extinguisher System Components
D. Pressure Gauges
A. Fire Bottle Each container has a pressure gauge which
The fire bottles are made of stainless steel, indicates pressure of the extinguishing agent.
with mounting lugs permanently attached. The gauges have a green band from 500-1000
The fire bottle is designed for a service psig (3447-6895 kPa) and are graduated in
pressure of 750 psig (5171 kPa). with a burst 100 psig (689 kPa) increments with a accuracy
pressure of 2900 (19,995 kPa). The fire bottles of plus or minus 30 psig (207 kPa).
contain 60 cu in (983 cu cm) of Halon 1301, Each gauge provides an electrical signal to the
and are pressurized with nitrogen gas to 750 Integrated Instrument Display System (IIDS)
psig (5171 kPa) @ 70F (21C). display (TANK PRESS LO) when pressure
drops to 250 25 psig (1724 172 kPa).
B. Dual Valves/Outlet Ports
E. Filler Ports
The valve/outlet ports swivel 360 and are
opened by an electrically activated discharge Each container has a filler port for installation
cartridge. The cartridges are armed for firing of the extinguishing agent and pressurized
when the fuel shutoff valves are placed in the gas. A safety outlet is incorporated as a
OFF position. The cartridges are fired when diaphragm to relieve excessive pressure in the
the bottle discharge switch on the fuel system container at 1700-2000 psig (11,721-13,790
panel is placed in the primary or alternate kPa) or when ambient temperature exceeds
position. 210 F (99 C).
Page 1
26-20-20 Revision 4
PRESSURE GAUGE
FILLER PORT
(RED PORT)
PRIMARY
CARTRIDGE (BLUE PORT)
ALTERNATE
CARTRIDGE
DISTRIBUTION TUBE
LEFT SIDE
DISTRIBUTION TUBE
RIGHT SIDE
REF
ENGINE DECK
DISCHARGE
TUBE
REF
FIRE BOTTLE
ENGINE DECK
ASSEMBLY
DISCHARGE
TUBE
OUTLET
PORT
CROSS FLOW OUTLET
TUBES PORT 9G26007
Figure 1. Fire Extinguisher System
Page 2
Revision 4 26-20-20

FAULT ISOLATION
1. Fire Extinguisher System Troubleshooting tables should be used with
Troubleshooting system schematics, electrical wiring diagrams,
manual.
brief summary of fire extinguisher system Comprehensive wiring diagrams are available
faults which may be encountered (Ref. in the Rotorcraft Maintenance Manual
Table 101). CSP-900RMM-3.
Table 101. Troubleshooting
TANK PRESS LO displayed Faulty wiring. Test and repair wiring (1). 980000
on IIDS with fire bottle
Faulty gauge. Replace fire bottle. 262020
gauge indicating within
acceptable limits. Faulty IIDS. Replace IIDS. 953000
Fire bottle gauge indicates Container leaking. Replace fire bottle. 262020
below acceptable pressure
limits. Faulty gauge. Replace fire bottle. 262020
Fire bottle gauge indicates Faulty wiring. Test and repair wiring (1). 980000
below 250 psig (1724 kPa),
TANK PRESS LO not
displayed on IIDS. Faulty IIDS. Replace IIDS. 953000
Cartridge did not discharge FUEL SHUTOFF valve Check FUEL SHUTOFF valve 960000
extinguishing agent. switch not positioned to position.
OFF.
Circuit breaker FIRE HRD Set or reset circuit breaker 960000
not set.
Faulty FIRE HRD circuit Replace circuit breaker. 960000
breaker.
Faulty wiring. Test and repair wiring (1). 980000
Faulty PRI/ALT select Replace switch. 960000
switch.
Faulty FUEL SHUTOFF Replace switch. 960000
valve switch.
Faulty discharge cartridge. Replace discharge cartridge. 262020
ACFTFALT=12, IIDS sensor Faulty wiring. Test and repair wiring (1). 980000
fault for TANK PRESS LO.
Faulty IIDS. Replace IIDS. 953000
NOTES:
(1) Disconnect electrical connectors from discharge cartridge, and install shunt plug covers before trouble
shooting wiring faults.
Page 101
26-20-20 Revision 4
A604 A704
ENGINE/FUEL CONTROL PANEL RH FIRE BOTTLE
S6 P509 J2
L FUEL SHUTOFF 28VDC
SWITCH A ALTERNATE LEFT
RTN
1 CLOSED B CARTRIDGE
2
3 OPEN
P508 J1
4 SELECT 28VDC
5 A PRIMARY RIGHT
RTN
6 OFF B CARTRIDGE
A620
W125 P512 J3
S7
CB32
R FUEL SHUTOFF C
J1 P130 FIRE HRD PRESSURE
SWITCH P375 J1 A
2 1 CLOSED SENSOR
3 OPEN A 24 5A BAT
BUS
4 SELECT
5
6 OFF
A705
W125 W307 LH FIRE BOTTLE
S8
BOTTLE DISCHARGE J302 P302 P507 J1
SWITCH 3 PRI 28VDC
B 1 A PRIMARY LEFT
2 OFF RTN B
1 ALT GS301-C E 2 CARTRIDGE
C 3
6 PRI GS303-E E 4
5 D 5
OFF P510 J2
4 ALT GS305-A E 6
Y 7 A 28VDC ALTERNATE
RIGHT
GS307-A E 8 B RTN
CARTRIDGE
A2 A612
IIDS W122 FWD INTERCONNECT PANEL
J5 P105 P170 J3 J2 P173 P511 J3
PRESSURE LO P302-SP1
TANK PRESS LO Z 10 22 9 A
PRESSURE
P302-SP2 SENSOR
RTN
E 10 C
GS301-A
9G26008A
Figure 101. Fire Extinguisher System Wiring Diagram
Page 102
Revision 4 26-20-20

1. Fire Extinguisher System Inspection (10). Inspect fire bottle pressure gauge for
condition, dented or broken gauge,
(1). Remove engine cowl assemblies L260 broken glass, and legible range mark
and R260 (Ref. Section 06-00-00). ing. Replace fire bottle as required.
(2). Inspect left and right distribution tubes (11). Fire bottle above minimum serviceable
for obstruction, restrictions, dents, and pressure (Ref. Table 201).
scratches. Maximum allowed dent
depth 0.015 in (0.381 mm) or scratch
Table 201. Minimum Serviceable Fire Bottle
depth 0.0035 in (0.0889 mm).
Pressure
(3). Open baggage compartment door L262 Temperature Gauge Reading
C F PSIG
(4). Inspect fire bottle primary and alter
nate discharge port for cracks, corro 40.0 40 395
sion, chafing, or scoring. Use bright 34.4 30 420
light and 10 power magnifier. No
28.9 20 450
discrepancies allowed.
23.3 10 465
(5). Inspect discharge cartridge connector
for condition and security. Repair or 17.8 0 485
replace as required. 12.2 +10 500
(6). Inspect fire bottle mounting brackets 6.7 +20 520
1.1 +30 555
(7). Inspect fire bottle assembly for security, +4.4 +40 585
dents, scratches and unserviceable
condition. Replace as required. +10.0 +50 625
Maximum allowed, dent depth 0.063 +15.6 +60 660

in per 1.0 in (0.063 mm per mm) +21.1 +70 700
average dent diameter or scratch
depth 0.005 in (0.125 mm). +26.7 +80 745
+32.2 +90 780
(8). Inspect discharge tube assemblies for
dents, scratches and unserviceable +37.8 +100 820
condition. Maximum allowed dent +43.3 +110 885
depth depth 0.015 in (0.381 mm) or
scratch depth 0.0035 in (0.0889 mm). +48.9 +120 950
(9). Inspect crossflow tube assemblies for (12). Close baggage compartment door L262
dents, scratches and unserviceable (Ref. Section 06-00-00).
condition. Maximum allowed dent
depth depth 0.015 in (0.381 mm) or (13). Install engine cowl assemblies L260
scratch depth 0.0035 in (0.0889 mm). and R260 (Ref. Section 06-00-00).
Page 201
26-20-20 Revision 4
2. Discharge Cartridge Bridgewire (8). Install shunt plug cover onto discharge
Resistances Test cartridge.
(Ref. Figure 201) (9). Remove discharge cartridge from
discharge cartridge safety chamber
Special Tools (T2026).
(Ref. CSPSPM)
(10). Install discharge cartridge into fire
Item Nomenclature
bottle.
T1003 Digital Multimeter, Portable
T1006 Shunt Plug Cover
T2026 Chamber, Safety
11/02
(1). Install wire from discharge cartridge
safety chamber (T2026) to ground.
SHUNT PLUG COVER
(2). Attach technician ground strap to Manufacture
Date CARTRIDGE
discharge cartridge safety chamber
(T2026) and test ground.
A
(3). Remove discharge cartridge from fire
bottle with shunt plug cover installed.
1.00 0.10 OHMS
Test meter which passes more
CAUTION than 50 milliamperes current B
may damage discharge cartridge, reducing
cartridge life. Higher current may cause dis CARTRIDGE
SCHEMATIC
charge cartridge to detonate.
Fire Extinguisher
9G26-014A
Figure 201. Discharge Cartridge Bridgewire

Resistance Test
(4). Attach free end of technician ground
strap to wrist of test technician. 3. Service Life Limit of Discharge Cartridges
(5). Thread discharge cartridge, with shunt (1). Verify manufacture date stamped on
plug cover installed, into discharge discharge cartridges ( Ref. Figure 201).
cartridge safety chamber (T2026).
(2). Remove discharge cartridges that have
(6). Remove shunt plug cover (T1006). reached service life limit (Ref. Chapter
04).
(7). Using digital multimeter (T1003)
measure discharge cartridge bridgewire (3). Return expired discharge cartridges to
resistance (Pin A to Pin B) 0.90-1.10 Mass Systems, Inc. or an approved
ohms. Replace cartridge if required. service-repair facility.
Page 202
4. Fire Bottle 5. Shipment of Fire Bottles and Discharge

Cartridges
A. Hydrostatic Testing Of Fire Bottle
Special Tools
NOTE: (Ref. CSPSPM)
Hydrostatic testing of pressure cylinders Item Nomenclature
used in aircraft is a U.S. Department of T1006 Shunt Plug Cover
Transportation requirement.
If a pressure cylinder hydrostatic test is A. Shipment of Charged Fire Bottles
not due during a scheduled inspection, it
can be hydrostatic tested after its due NOTE: A fire bottle that is past the hydrostatic
date at the next scheduled inspection. test due date, can be transported or shipped
in the charged condition if it was filled be
Cylinders which have reached their hy
fore the hydrostatic test due date.
drostatic test due date cannot be re
charged or installed until hydrostatically Pressurized fire bottles are clas
tested. CAUTION sified as an `ÈXPLOSIVE MA
TERIAL and must be identified as such to
(1). Return fire bottles with out dated the transportation carrier.
hydrostatic service life to Mass Sys
tems, Inc. or an approved service-re Any charged fire bottle that is being returned
pair facility. to the manufacturer or a service repair facility
must:
B. Weight Verification Of Fire Bottle
(1). Have discharge outlets and cartridges
installed. If outlet and cartridge are not
(1). Remove fire bottle.
available, the outlet ports must be
protected with special safetied metal
NOTE: Fire bottles must have weight verifica caps.
tion with discharge cartridges removed.
(2). Be shunted with a conductive shunt
Fire Extinguisher plug cover (T1006) or wire across
exposed terminal shorted to discharge
cartridge connector case.
(3). Be packed properly in a suitable
container. The container markings and
(2). Remove discharge cartridges from fire shipping documents must comply with
bottle with shunt plug covers installed. the requirements of the Department of
Transportation (DOT).
NOTE: Weight verification must be on a scale
with an accuracy of plus/minus 0.16 oz (4.54 (4). Have the specific DOT exemption
g). Number on the container and shipping
documents. The exemption Number is
(3). Weight shall not vary from marked stamped or engraved on the fire bottle
weight of last weighing by more than mounting lugs.
1.6 oz (45.36 g).
B. Shipment of Discharge Cartridge
(4). Return fire bottles with more than Discharge cartridges are classi
allowed weight difference to an ap CAUTION fied as an `ÈXPLOSIVE MA
proved service-repair facility. TERIAL and must be identified as such to
the transportation carrier.
(5). Install discharge cartridges into fire
bottle. Any discharge cartridge that is being returned
to the manufacturer or a service repair facility
(6). Install fire bottle. must:
Page 203
(1). Be shunted with a conductive rubber (a). Detach connectors P508 from (red
shunt plug (Mass Systems, Inc. port) primary discharge cartridge (9),
PN 306212) or wire across exposed P509 (blue port) alternate discharge
terminal shorted to discharge cartridge cartridge (10), and pressure gage
connector case. P512 (11).
(2). Be packed properly in a suitable (b). Install (T1006) shunt plug covers to
container. The container markings and primary and alternate discharge
shipping documents must comply with cartridges.
the requirements (DOT). (c). Disconnect crossflow tube assemblies
NOTE: The explosive charge in each discharge (12 and 4) and right side discharge
cartridge is approximately 0.4 grams. tube assembly (13).
6. Fire Bottle Assembly from fire bottle mounting support (24)
(Ref. Figure 202) or (25) and remove fire bottle assembly.
B. Fire Bottle Assembly Installation
Consumable Materials Fire Extinguisher
(Ref. CSPSPM)
Item Nomenclature
C702 Lockwire
Special Tools (1). Install fire bottle assembly and install

(Ref. CSPSPM) screws (18) and washers (19) into fire
Item Nomenclature bottle mounting support (24) or (25).
Torque screws.
T1006 Shunt Plug Cover
NOTE:
Red and blue outlet ports can be rotated
A. Fire Bottle Assembly Removal
for installation alignment by loosening
(1). Remove electrical load center (Ref. jam nuts.
CSP-900RMM-3, Section 96-00-00). When ports are aligned with tubing,
torque jam nut to 25-30 ft lb (33.9-40.7
Fire Extinguisher N m) and safety using lockwire (C702).
Do not remove outlet port from
CAUTION fire bottle assembly.
(2). Left fire bottle assembly:
(2). Left fire bottle assembly:
(a). Connect left side discharge tube
(a). Detach connectors P507 from (red assembly and crossflow tube assem
port) primary discharge cartridge (1), blies. Torque tube assemblies.
P510 from (blue port) alternate
discharge cartridge (2), and pressure (b). Remove shunt plug cover (T1006).
gauge P511 (3).
(c). Attach connectors P507, P510, and
(b). Install shunt plug cover (T1006) to P511.
primary and alternate discharge (3). Right fire bottle assembly:
cartridges.
(a). Connect right side discharge tube
(c). Disconnect crossflow tube assemblies assembly and and crossflow tube
(4 and 12) and left side discharge assemblies. Torque tube assemblies.
tube assembly (5).
(b). Remove shunt plug cover (T1006)
(3). Right bottle assembly and attach electrical connector plugs.
Page 204
(c). Attach connectors P508, P509, and B. Discharge Cartridge Installation

P512.
CAUTION
(4). Install electrical load center (Ref.
CSP-900RMM-3, Section 96-00-00). Red coded discharge cartridge must be
installed in red coded discharge port.
7. Fire Extinguisher Discharge Cartridge Blue coded discharge cartridge must be
installed in blue coded discharge port.
(Ref. Figure 202) Fire Extinguisher
(Ref. CSPSPM)
Item Nomenclature (1). Install discharge cartridge into fire
C702 Lockwire bottle discharge outlet port. Torque
cartridge 90-100 in lb (10.16-11.29
Special Tools
N m) and safety with lockwire (C702).
(Ref. CSPSPM) (2). Remove shunt plug cover (T1006).
Item Nomenclature
(3). For installation of fire extinguisher
T1006 Shunt Plug Cover discharge cartridge in position:
(a). Left primary, attach connector P507
A. Discharge Cartridge Removal to red port (6).
(b). Left alternate, remove attach P510
(1). Remove electrical load center (Ref.
to blue port (7).
(c). Right primary, attach connector P508
Fire Extinguisher to red port (14).
(d). Right alternate, attach P509 to blue
port (15).
(2). For removal of fire extinguisher CSP-900RMM-3, Section 96-00-00).
discharge cartridge in position: 8. Discharge Tube Assembly
(a). Left primary, detach connector P507 (Ref. Figure 202)
(1) from red port (6). A. Discharge Tube Assembly Removal
(b). Left alternate, detach P510 (2) from NOTE: This task is typical for left and right
blue port (7). Discharge Tube Assembly removal.
(1). Remove electrical load center (Ref.
(c). Right primary, detach connector
P508 (9) from red port (14).
(2). Disconnect discharge tube assembly (5)
(d). Right alternate, detach P509 (10) or (13) connector nuts from deck fitting
from blue port (15). (30) or (31) and fire bottle discharge
port fitting (6) or (14) and remove
(3). Install shunt plug cover (T1006) onto discharge tube assembly.
discharge cartridge.
B. Discharge Tube Assembly Installation
(4). Cut lock wire from discharge cartridge NOTE: This task is typical for left and right
and remove cartridge from fire bottle. Discharge Tube Assembly installation.
Page 205
(1). Install discharge tube assembly (3). Loosen distribution tube assembly
connector nuts to deck fitting and fire connector nut (17) to deck fitting (30) or
bottle discharge port fitting. Torque (31) and remove distribution tube.
nuts (Ref. CSP-SPM).
B. Distribution Tube Assembly Installation
CSP-900RMM-3, Section 96-00-00). NOTE: This task is typical for left and right
Distribution Tube Assembly installation.
9. Distribution Tube Assembly
(Ref. Figure 202) (1). Install distribution tube assembly onto
deck fitting.
A. Distribution Tube Assembly Removal
(2). Install upper and lower support clamps,
NOTE: This task is typical for left and right screws, washers, and nuts. Torque nuts
Distribution Tube Assembly removal. (Ref. CSP-SPM).
(1). Remove engine cowl assemblies L260 or
R260 (Ref. Section 06-00-00). (3). Torque distribution tube assembly
connector nut (Ref. CSP-SPM).
nuts (22) from upper and lower support (4). Install engine cowl assemblies L260 or
clamps (23) and remove clamps. R260 (Ref. Section 06-00-00).
Page 206
Revision 4 26-20-20
8 16
15 3 6
1
10
11
LOOKING AFT 24 (RH)
20
21 25 (LH)
22
23
20
21
26 22
23
27
18 (3 PL)
20 20 19 (3 PL)
21 21
22 22
23 23
29
30 17 (2 PL) 28
LOOKING FORWARD
28
32 31
13
7
14
5 4
12 9
2
9G26-015
Figure 202. Fire Extinguisher System
Page 207
26-20-20 Revision 4

1. ELECTRICAL CONNECTOR P507, PRIMARY 15. ALTERNATE OUTLET (BLUE) PORT, RIGHT FIRE
DISCHARGE CARTRIDGE, LH BOTTLE
2. ELECTRICAL CONNECTOR P510, ALTERNATE 16. PRESSURE GAUGE, RIGHT FIRE BOTTLE
DISCHARGE CARTRIDGE, LH 17. NUT, DECK FITTING
3. ELECTRICAL CONNECTOR P511, PRESS GAUGE, LH 18. SCREW
4. TUBE ASSEMBLY, CROSSFLOW 19. WASHER
5. TUBE ASSEMBLY, DISCHARGE, LEFT SIDE 20. SCREW
6. PRIMARY OUTLET (RED) PORT, LEFT FIRE BOTTLE 21. WASHER
7. ALTERNATE OUTLET (BLUE) PORT, LEFT FIRE 22. NUT
BOTTLE 23. CLAMP
8. PRESSURE GAUGE, LEFT FIRE BOTTLE 24. MOUNTING SUPPORT BRACKET, RH
9. ELECTRICAL CONNECTOR P508, PRIMARY 25. MOUNTING SUPPORT BRACKET, LH
DISCHARGE CARTRIDGE, RH 26. DISTRIBUTION TUBE, LEFT SIDE
10. ELECTRICAL CONNECTOR P509, ALTERNATE 27. DISTRIBUTION TUBE, RIGHT SIDE
DISCHARGE CARTRIDGE, RH 28. DISCHARGE CARTRIDGE
11. ELECTRICAL CONNECTOR P512, PRESS GAUGE, RH 29. FILLER/PRESSURE RELIEF PORT
12. TUBE ASSEMBLY, CROSSFLOW 30. DECK FITTING, STRAIGHT
13. TUBE ASSEMBLY, DISCHARGE, RIGHT SIDE 31. DECK FITTING, ELBOW
14. PRIMARY OUTLET (RED) PORT, RIGHT FIRE BOTTLE 32. CONNECTOR NUT, TUBING (TYPICAL)
Page 208
Revision 4 26-20-20
Chapter
FUEL SYSTEM
TABLE OF CONTENTS
28-00-00 Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A

1. Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Fuel Storage Subsystem . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
A. Fuel Cell . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
B. Fuel Vents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
C. Gravity Filler Port Fueling/Defueling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
D. Fuel Sump Drain Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
E. Fuel Quantity Probes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
3. Fuel Distribution Subsystem . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
A. Fuel Booster Pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
B. Fuel Supply Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
C. Fuel Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
D. Fuel Shutoff / Crossfeed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
E. Fuel Transfer System (902 CONFIG) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Figure 1.Fuel System (900 CONFIG) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Figure 2.Fuel System (902 CONFIG) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Figure 3.Fuel System Schematic (900 CONFIG) . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Figure 4.Fuel System Schematic (902 CONFIG) . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Fault Isolation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
1. Fuel System Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Table 101.Fuel System Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Figure 101.Fuel Pressure Switch Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . 105
Figure 102.Fuel Boost Pump Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
Figure 103.Fuel Boost Pump Wiring Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
Figure 104.Fuel Quantity Gauging Probes Wiring Diagram (900 CONFIG) . . . 106
Figure 105.Fuel Quantity Gauging Probes Wiring Diagram (902 CONFIG) . . . 107
Figure 106.Fuel Quantity Probes Schematic (900 CONFIG) . . . . . . . . . . . . . . . . 108
Figure 107.Fuel Quantity Probes Schematic (902 CONFIG) . . . . . . . . . . . . . . . . 108
Figure 108.Fuel Shut-Off and Crossfeed Valve Wiring Diagram
(900 CONFIG - PW206A) (Sheet 1 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . 109
Figure 109.Fuel Shut-Off Valve Wiring Diagram
(902 CONFIG, 900 CONFIG - PW207E) (Sheet 1 of 2) . . . . . . . . . . . 111
Figure 110.Fuel Shut-Off Valves / Crossfeed Valve Wiring Schematic (Typical) 112
1. Fuel Cell . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
A. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
Page i

B. Contaminated Fuel Cell Procedure (902 CONFIG) . . . . . . . . . . . . . . . . . . . . . . . . . . 201
C. Contaminated Fuel Cell Procedure (900 CONFIG) . . . . . . . . . . . . . . . . . . . . . . . . . . 203
1. Fuel Cell . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
A. Fuel Cell Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
B. Fuel Cell Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 402
Figure 401.Fuel System (900 CONFIG) (Sheet 1 of 3) . . . . . . . . . . . . . . . . . . . . . . 405
2. Fuel Cell Access Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 408
A. Fuel Cell Access Cover Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 408
B. Fuel Cell Access Cover Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 408
Figure 402.Fuel Cell Access Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 409
3. Centrifugal Fuel Booster Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 409
A. Centrifugal Fuel Booster Pump Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 409
B. Centrifugal Fuel Booster Pump Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 410
C. Centrifugal Fuel Booster Pump Umbrella Shaped Check Valve Removal . . . . . . 411
D. Centrifugal Fuel Booster Pump Umbrella Shaped Check Valve Installation . . . 411
Figure 403.Centrifugal Fuel Booster Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 412
4. Centrifugal Fuel Booster Pump Cartridge Replacement . . . . . . . . . . . . . . . . . . . . . . . 413
A. Fuel Booster Pump Cartridge Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 413
B. Fuel Booster Pump Cartridge Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 413
Figure 404.Centrifugal Fuel Booster Pump (Cartridge Only) Replacement . . . 415
5. Forward Fuel Gauging Probe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 415
A. Forward Fuel Gauging Probe Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 415
B. Forward Fuel Gauging Probe Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 416
6. Aft Fuel Gauging Probe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 416
A. Aft Fuel Gauging Probe Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 416
B. Aft Fuel Gauging Probe Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 417
Figure 405.Fuel Gauging Probes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 417
Figure 406.Fuel Pump, Gauging, and Transfer Systems (902 CONFIG) . . . . . . 418
7. Gravity Fill Port Filler Neck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 419
A. Gravity Fill Port Filler Neck Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 419
B. Gravity Fill Port Filler Neck Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 419
8. Fuel Fill Port Check Valve Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 420
A. Fuel Fill Port Check Valve Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 420
B. Fuel Fill Port Check Valve Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 420
Figure 407.Gravity Fill Port Filler Neck and Check Valve . . . . . . . . . . . . . . . . . . 421
9. Range Extender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 422
Page ii

A. Range Extender Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 422
B. Range Extender Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 422
Figure 408.Range Extender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 422
10. Single Port Fuel Vent Float/Rollover Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 423
A. Single Port Fuel Vent Float/Rollover Valve Removal . . . . . . . . . . . . . . . . . . . . . . . . 423
B. Single Port Fuel Vent Float/Rollover Valve Installation . . . . . . . . . . . . . . . . . . . . . 423
Figure 409.Single Port Fuel Vent Float/Rollover Valves . . . . . . . . . . . . . . . . . . . . . 424
11. Dual Port Fuel Vent Float/Rollover Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 425
A. Dual Port Fuel Vent Float/Rollover Valve Removal . . . . . . . . . . . . . . . . . . . . . . . . . 425
B. Dual Port Fuel Vent Float/Rollover Valve Installation . . . . . . . . . . . . . . . . . . . . . . 425
Figure 410.Dual Port Fuel Vent Float/Rollover Valve . . . . . . . . . . . . . . . . . . . . . . . 427
12. Fuel Vent System Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 428
A. Fuel Vent Components Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 428
B. Fuel Vent Components Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 428
Figure 411.Fuel Vent System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 430
13. Fuel Sump Drain Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 431
A. Fuel Sump Drain Valve Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 431
B. Fuel Sump Drain Valve Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 431
14. Fuel Sump Drain Valve Control Assembly (Fwd and Aft) . . . . . . . . . . . . . . . . . . . . . . 431
A. Fuel Sump Drain Valve Control Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . 431
B. Fuel Sump Drain Valve Control Assembly Installation . . . . . . . . . . . . . . . . . . . . . . 432
Figure 412.Fwd and Aft Fuel Sump Drain Valve and
Drain Valve Control Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 432
15. Fuel Cell Frangible Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 433
A. Fuel Cell Frangible Valve Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 433
B. Fuel Cell Frangible Valve Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 433
Figure 413.Fuel Cell Frangible Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 435
16. Fuel Interconnect Tee Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 436
A. Fuel Interconnect Tee Fitting Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 436
B. Fuel Interconnect Tee Fitting Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 436
17. Fuel Pressure Switch Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 437
A. Fuel Pressure Switch Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 437
B. Fuel Pressure Switch Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 438
Figure 414.Fuel Interconnect Tee Fitting and Fuel Pressure Switch . . . . . . . . . 439
18. Fuel Shut-Off Valve Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 439
A. Fuel Shut-Off Valve Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 439
B. Fuel Shut-Off Valve Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 440
Page iii

Figure 415.Fuel Shut-Off Valve Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 441
19. Crossfeed Fuel Shut-Off Valve (900 CONFIG) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 441
A. Crossfeed Fuel Shut-Off Valve Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . 441
B. Crossfeed Fuel Shut-Off Valve Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . 442
Figure 416.Crossfeed Fuel Shut-Off Valve (900 CONFIG) . . . . . . . . . . . . . . . . . . 443
20. Engine Deck Frangible Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 443
A. Engine Deck Frangible Valve Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 443
B. Engine Deck Frangible Valve Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 444
Figure 417.Engine Deck Frangible Valves (900 CONFIG) . . . . . . . . . . . . . . . . . . . 445
21. Engine Fuel Feed Hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 446
A. Engine Fuel Feed Hose Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 446
B. Engine Fuel Feed Hose Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 446
Figure 418.Engine Fuel Feed Hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 447
22. Fuel Supply Tubes, Hoses and Shrouds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 448
A. Fuel Supply Tubes, Hoses and Shrouds Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . 448
B. Fuel Supply Tubes, Hoses and Shrouds Installation . . . . . . . . . . . . . . . . . . . . . . . . 448
23. Lower Fuel Supply Hoses and Shrouds (900 CONFIG) . . . . . . . . . . . . . . . . . . . . . . . . 449
A. Lower Fuel Supply Hoses and Shrouds Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . 449
B. Lower Fuel Supply Hoses and Shrouds Installation . . . . . . . . . . . . . . . . . . . . . . . . . 450
24. Lower Fuel Supply Hoses and Shrouds, Supplemental Fuel System (Option)
(900 CONFIG) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 451
A. Lower Fuel Supply Hoses and Shrouds, Supplemental Fuel System,
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 451
B. Lower Fuel Supply Hoses and Shrouds, Supplemental Fuel System,
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 452
Figure 419.Fuel Supply Tubes, Hoses and Shrouds (Sheet 1 of 3) . . . . . . . . . . . . 453
Figure 420.Fuel Supply Tube Spacer Installation Location (Sheet 1 of 2) . . . . . 457
25. In-line Check Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 458
A. Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 458
B. Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 458
C. Leak Check and Functional Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 459
Figure 421.In-Line Check Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 459
26. Jet Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 460
A. Jet Pump Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 460
B. Jet Pump Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 460
Figure 422.Jet Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 460
Inspection / Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601
1. General Inspections for the Fuel Cell . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601
Page iv

A. Fuel Cell Inspection - Fuselage Bottom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601
B. Fuel Cell Inspection - Fuselage Cavity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601
C. Fuel Cell Inspection - Internal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 602
2. Inspections for the Fuel Vent System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 604
A. Inspection of the Fuel Vent System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 604
3. Inspections for the Fuel Supply System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 605
A. Inspection of the Engine Fuel Feed Hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 605
B. Inspection of the Vapor Shroud Box, Cover Assembly and Vapor Shroud Hose . 605
Figure 601.Fuel Cell Leak Check/Pressure Test - Method 1 . . . . . . . . . . . . . . . . . 606
4. Fuel Cell Leak Check/Pressure Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 607
A. Fuel Cell Leak Check/Pressure Test Method 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 607
Figure 602.Fuel Cell Leak Check/Pressure Test - Method 2 . . . . . . . . . . . . . . . . . 610
B. Fuel Cell Leak Check/Pressure Test Method 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 611
Figure 603.Fuel Supply Vapor Shroud Leak Check / Pressure Test
(900 CONFIG) (Sheet 1 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 614
5. Fuel Supply Vapor Shroud Leak Check/Pressure Test . . . . . . . . . . . . . . . . . . . . . . . . . 615
A. Fuel Supply Vapor Shroud Leak Check/Pressure Test (900 CONFIG) . . . . . . . . . 615
B. Fuel Supply Vapor Shroud Leak Check/Pressure Test (900 CONFIG)
With Supplemental Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 616
Figure 604.Fuel Supply Vapor Shroud Leak Check/Pressure Test
(902 CONFIG) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 618
C. Fuel Supply Vapor Shroud Leak Check/Pressure Test (902 CONFIG) . . . . . . . . . 619
6. Operational Tests for the Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 620
A. Operation Test of the Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 620
Figure 605.Fuel System Panel / Electrical Master Panel . . . . . . . . . . . . . . . . . . . . 621
Figure 606.900 CONFIG - Fuel System IIDS Secondary Panel Display . . . . . . 622
Figure 607.902 CONFIG - Fuel System IIDS Secondary Panel Display . . . . . . 623
7. Operational Tests for the Fuel Distribution System . . . . . . . . . . . . . . . . . . . . . . . . . . . 624
A. Operational Test of the Fuel Booster Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 624
B. Operational Test of the Fuel Shut-Off Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 624
C. Operational Test of the Crossfeed Shut-Off Valve (900 CONFIG) . . . . . . . . . . . . 625
8. Functional Tests for the Fuel Quantity Indication System . . . . . . . . . . . . . . . . . . . . . 626
A. Functional Test of the Fuel Quantity Indication System . . . . . . . . . . . . . . . . . . . . . 626
Figure 608.Typical Fuel Density/Weight vs Temperature Fahrenheit/Celsius,
1 US Gallon/3.785 Liters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 627
9. Tests for the Fuel Cell . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 629
A. Integrity Test of the Longitudinal Baffle of the Fuel Cell (902 CONFIG) . . . . . . 629
Figure 609.Fuel Cell Baffle Cord Deflection (900 CONFIG) . . . . . . . . . . . . . . . . . 630
Page v

10. Inspections for the Fuel Cell Baffle Cord . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 630
A. Cord Deflection Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 630
Figure 610.Fuel Cell Baffles and Cord Routing (902 CONFIG) . . . . . . . . . . . . . . 631
Figure 611.Bowline and Half-Hitch Knots . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 632
11. Operational Tests for the Fuel Transfer System (902 CONFIG) . . . . . . . . . . . . . . . . 633
A. Normal Ground Attitude (3 Degrees Nose Up, 0 Degrees Roll) . . . . . . . . . . . . . . . 633
B. Normal Cruise Attitude (5 Degrees Nose Down, 0 Degrees Roll) . . . . . . . . . . . . . 634
12. Functional Tests for the Low Fuel Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 636
A. Functional Test of the Low Fuel Light (900 CONFIG) . . . . . . . . . . . . . . . . . . . . . . . 636
Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 801
1. Fuel Cell . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 801
A. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 801
2. Fuel Cell Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 801
A. Scuff Mark, Chafing, or Snag Damage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 801
B. Inner-Liner/Outer-Ply Damage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 801
C. Damage Limitations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 801
28-10-00 Supplemental Fuel System (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Supplemental Fuel Tank Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
3. Supplemental Fuel System Fuel Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
4. Supplemental Fuel System Fuel Vent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
5. Supplemental Fuel System Fuel Quantity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Figure 1.Supplemental Fuel System Installation (Sheet 1 of 2) . . . . . . . . . . . . . . 2
Fault Isolation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
1. Supplemental Fuel System Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Figure 101.Supplemental Fuel System Wiring Diagram . . . . . . . . . . . . . . . . . . . . 102
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
1. Supplemental Fuel Transfer Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
A. Supplemental Fuel Transfer Pump Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
B. Supplemental Fuel Transfer Pump Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
Figure 401.Supplemental Fuel Transfer Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 402
2. Supplemental Fuel Tank Filler Neck Adapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 403
A. Supplemental Fuel Tank Filler Neck Adapter Removal . . . . . . . . . . . . . . . . . . . . . 403
B. Supplemental Fuel Tank Filler Neck Adapter Installation . . . . . . . . . . . . . . . . . . . 403
Page vi

3. Supplemental Fuel System Gravity Fill Check Valve . . . . . . . . . . . . . . . . . . . . . . . . . . 404
A. Supplemental Fuel System Gravity Fill Check Valve Removal . . . . . . . . . . . . . . . 404
B. Supplemental Fuel System Gravity Fill Check Valve Installation . . . . . . . . . . . . 404
4. Supplemental Fuel System Filler Neck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 405
A. Supplemental Fuel System Filler Neck Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . 405
B. Supplemental Fuel System Filler Neck Installation . . . . . . . . . . . . . . . . . . . . . . . . . 405
Figure 402.Supplemental Fuel System Filler Neck . . . . . . . . . . . . . . . . . . . . . . . . . 406
5. Supplemental Fuel System Quantity Transmitter . . . . . . . . . . . . . . . . . . . . . . . . . . . . 406
A. Supplemental Fuel System Quantity Transmitter Removal . . . . . . . . . . . . . . . . . 406
B. Supplemental Fuel System Quantity Transmitter Installation . . . . . . . . . . . . . . . 407
6. Supplemental Fuel Tank Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 407
A. Supplemental Fuel Tank Cover Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 407
B. Supplemental Fuel Tank Cover Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 408
7. Supplemental Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 408
A. Supplemental Fuel Tank Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 408
B. Supplemental Fuel Tank Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 409
8. Supplemental Fuel Check Valve (CURRENT CONFIG) . . . . . . . . . . . . . . . . . . . . . . . 409
A. Supplemental Fuel Check Valve Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 409
B. Supplemental Fuel Check Valve Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 410
Figure 403.Supplemental Fuel System Installation (Sheet 1 of 3) . . . . . . . . . . . . 411
9. Supplemental Fuel Tank Foam Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 414
A. Supplemental Fuel Tank Foam Support Removal . . . . . . . . . . . . . . . . . . . . . . . . . . 414
B. Supplemental Fuel Tank Foam Support Installation . . . . . . . . . . . . . . . . . . . . . . . . 414
Figure 404.Supplemental Fuel Tank Foam Support Installation . . . . . . . . . . . . . 415
10. Supplemental Fuel Transfer System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 415
A. Supplemental Fuel Transfer System Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 415
B. Supplemental Fuel Transfer System Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 416
Figure 405.Supplemental Fuel Transfer System Installation . . . . . . . . . . . . . . . . 417
Inspection/Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601
1. Supplemental Fuel System Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601
A. Supplemental Fuel Tank Inspection - Fuselage External . . . . . . . . . . . . . . . . . . . 601
B. Supplemental Fuel Tank Inspection - Fuselage Internal . . . . . . . . . . . . . . . . . . . . 601
C. Supplemental Fuel Transfer Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 602
D. Supplemental Fuel Cavity Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 602
2. Supplemental Fuel Tank Leak Check/Pressure Test . . . . . . . . . . . . . . . . . . . . . . . . . . 603
A. Supplemental Fuel Tank Leak Check/Pressure Test Method 1
(Requires Floor Panel Removal) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 603
Page vii

Figure 601.Supplemental Fuel Tank Leak/Pressure Test Method 1
(Sheet 1 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 604
B. Supplemental Fuel Tank Leak Check/Pressure Test Method 2
(Does Not Require Floor Removal) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 605
3. Supplemental Fuel Quantity Operational Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 606
4. Supplemental Fuel Transfer Operational Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 606
Figure 602.Supplemental Fuel Transfer Operational Test . . . . . . . . . . . . . . . . . . . 607
Modification/Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 801
1. Main Fuel Tank Cover Modification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 801
Figure 801.Main Fuel Tank Cover Modification . . . . . . . . . . . . . . . . . . . . . . . . . . . . 801
2. Aft Vent Tube Modification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 802
Figure 802.Aft Vent Tube Modification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 802
3. Right Outboard Baggage Floor Panel Modification . . . . . . . . . . . . . . . . . . . . . . . . . . . . 803
Figure 803.Right Outboard Baggage Floor Panel Modification . . . . . . . . . . . . . . 803
4. Supplemental Fuel Tank Support Foam Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 804
5. Supplemental Fuel Tank Cavity Vapor Barrier Repair . . . . . . . . . . . . . . . . . . . . . . . . 804
6. Fuel Neck Cover Seal Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 804
7. Supplemental Fuel Check Valve Modification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 805
Figure 804.Supplemental Fuel Check Valve Modification . . . . . . . . . . . . . . . . . . . 806
Page viii
Section
280000
Fuel System
FUEL SYSTEM
1. Fuel System A. Fuel Cell
(Ref. Figure 1) The fuel cell is a crash-resistant bladder type

cell.
The fuel system stores and distributes fuel to
Fuel cell capacity without range extender is
the engines. The fuel system is designed for
1014 lb (460 kg)(149.0 US gallons (564.0
maximum safety so no single failure can result
liters)) of fuel, 994 lb (451 kg)(146.2 US
in fuel starvation. The fuel system has been
gallons (553.4 liters)) useable fuel.
designed to maximize safety by isolating and
sealing the fuel sources. All fuel lines and Fuel cell capacity with range extender is
valves are enclosed in a shroud system that is 1097 lb (498 kg)(161.2 US gallon (610.2
connected to an overboard drain. The shroud liters)) of fuel, 1078 lb (489 kg)(158.5 US
and drain systems and isolate fuel leaks from gallons (600 liters)) useable fuel.
the helicopter and drain the leaking fuel
overboard. The cell is constructed of a two-ply layer of
flexible, high tenacity Nitrile-coated woven
The fuel system consists of the Fuel Storage nylon fabric, coatings, adhesive, and a nylon
Subsystem and the Fuel Distribution Subsys film barrier. The internal ply of Nitrile-coated
tem. fabric contains the fuel and provides internal
protection of the nylon film barrier. The film
2. Fuel Storage Subsystem barrier keeps fuel from diffusing through the
fuel cell wall. The outer ply of Nitrile-coated
The fuel storage subsystem stores and fabric provides external protection to the film
monitors fuel available for operation of the barrier.
engines. Fuel is carried in a bladder type fuel
cell located below the cabin compartment floor. The inside of the fuel cell, is divided by two
Access to the fuel cell is provided by removable lateral baffles which reduce fuel sloshing
floor panels. The cell is supported by the during changes in flight attitudes. The baffles
passenger compartment floor, fuselage have openings across their face to allow fuel to
structure, and special fasteners. pass through them. This reduces the load on
the baffles and provides even fuel distribution
The fuel storage subsystem consists of the within the cell. A baffle is installed longitudi
following components: nally between the boost pumps. The baffle
evenly distributes fuel to each fuel booster
Fuel Cell - Stores fuel for operation of the pump. 902 CONFIG - The longitudinal baffle
engines. is the full length of the fuel cell. The baffle
separates the fuel cell into left and right
Fuel Vents - Vent fuel cell vapors to the cavities to isolate 20 minutes of fuel to each
atmosphere. engine in critical flight attitudes. The fuel cell
is equipped with four access cover openings
Filler Port - Provides a service point for which allow access to the fuel booster pumps
refueling or defueling during maintenance and fuel quantity probes.
operations.
Fuel cell support ribs are installed laterally
Fuel Drain Valves - Provides a manual drain between the fuel cell and the forward and aft
for the fuel cell at the lowest point in the fuel lower fuselage cavities of the fuselage struc
storage system. ture. A liner panel assembly installed over the
ribs contours the fuel cell. Two fuel cell cavity
Fuel Quantity Probes - Monitors fuel foam supports installed on the aft outboard
quantity level and provides an electrical signal portion of the liner support the aft outboard
to the Integrated Instrument Display System portion of the fuel cell. In the event of a fuel
(IIDS). leak, the support ribs prevent fuel from being
Page 1
trapped between the cell and the helicopter D. Fuel Sump Drain Valves
structure. The liner ribs route leaking fuel for
drainage through fuselage drain holes. Two fuel sump drain valves are located on the
fuel cell sump plate. The sump plate is
B. Fuel Vents centered on the bottom forward portion of the
fuel cell. The drain valves are spring loaded,
Two forward and two aft vent/rollover valves normally closed, poppet drain valves. The
are located on the top side of the fuel cell and valves are actuated by push cables to evacuate
vent fuel to the atmosphere. The single fuel from the fuel cell. Fuel exits the fuselage
vent/rollover valves are located at the forward through drain hoses.
right corner and the aft left corner of the fuel
cell. The dual vent/rollover valves are located E. Fuel Quantity Probes
at the forward left corner and rear right corner
of the fuel cell. The dual vent/rollover valves The fuel quantity probes are powered by
are attached to standpipes, which prevent any 24-28 vdc current and consist of two capaci
fuel from draining overboard. Each single tance type sensor probes bolted to the fuel cell
vent/rollover valve is connected by hoses and sump plate. The forward and aft gauging
tubes to a dual vent/rollover valve. probes output signals are processed by the
Integrated Instrument Display System (IIDS)
Each vent/rollover valve is a normally open to illuminate the fuel quantity bar graph and
poppet type float valve. The valve automatical digital readout on the IIDS display.
ly closes to prevent fuel loss through the vent
system. It's primary purpose is to allow the The aft gauging probe has an independently
fuel cell to vent to the atmosphere. It's powered 24 to 28 Vdc fuel low level detector
secondary function is to close when the (thermistor). The fuel low warning indicator on
helicopter is outside of an 855 pitch or roll the IIDS illuminates when the low level
angle. The valve also closes when fuel levels in warning detector is activated (900 CONFIG -
the fuel cell reach the float. 97 to 117 lb (44.0 to 53.1 kg) of fuel remain
ing) (902 CONFIG - 97 to 127 lb (44.0 to
Flame arrestors are located in the outlet of 57.6 kg) of fuel remaining).
each standpipe to prevent any potential flames
from reaching the vent/rollover valves and fuel (900 CONFIG - PW207E) The left FUEL
cell. low level warning tic mark on the IIDS does
not operate for aircraft upgraded from
C. Gravity Filler Port Fueling/Defueling PW206A to PW207E engines.
Refueling and defueling is through a gravity The fuel quantity bar graph on the IIDS
filler port located on the right side of the displays the fuel quantity status, fuel low
fuselage at the forward section of the fuel cell. caution bars, and fuel low warning bar. The
A check valve attaches to the filler neck fuel quantity bars (green) indicate fuel in 50
fitting. The filler neck fitting is secured to the pound increments. The fuel low caution bars
fuselage. The check valve is located within the (yellow) indicate fuel in 150 lb (68.0 kg)
fuel cell. The valve opens when the fuel cap is increments and illuminate when fuel quantity
removed by pulling a lanyard for refueling and is 151 to 300 lb (68.5 to 136.1 kg). The fuel
defueling operations. The valve closes when low warning bar (red) illuminates when fuel
the fuel cap is secured to the filler neck fitting quantity is 150 lb (68.0 kg). The digital
preventing fuel leakage. readout displays pounds of available fuel in a
numeric value.
An optional range extender filler port
increases fuel capacity by 12 US gallons (45.4 902 CONFIG - The forward fuel probe also
liters) by allowing the fuel cell to fill complete has a low level sensor. The forward fuel probe
ly. low fuel warning indicates low fuel in the left
fuel cell cavity. The aft fuel probe low fuel
(902 CONFIG) The lanyard attached to the indicator is for the right cavity. The IIDS
fuel cap also opens a flapper valve in the display will identify the warning as left or
longitudinal baffle to decrease refueling time. right low fuel.
Page 2
3. Fuel Distribution Subsystem canister cover are covered by an umbrella

check valve. The umbrella valve permits fuel
The fuel distribution subsystem supplies fuel vapors in the pump cartridge assembly to
to the engines. Fuel is supplied from the fuel escape, avoiding impeller cavitation. The
cell through supply lines located in the aft canister cover umbrella check valve also
bulkhead of the baggage compartment. prevents fuel leakage when the cartridge
assembly is removed.
The fuel distribution subsystem consists of the
following components: The impeller is driven directly by the dc motor
shaft. The bearings in the dc motor are
Fuel Booster Pumps - Pressurizes fuel for hydrodynamically lubricated. Once shaft
engine operation. rotation begins, there is no contact between
Fuel Supply Lines - Routes pressurized fuel the shaft and the bearings.
from the fuel cell to the engines. Three bleed holes are located in an adapter
Shutoff Valves - Shuts off the fuel supply to plug on top of the pump housing assembly
the engines. near the fuel inlet screen. The bleed holes are
covered by an umbrella check valve. The
Fuel Pressure Switch - Measures fuel umbrella check valve allows fuel vapors
pressure and sends a signal to the IIDS. entering the pump housing assembly to
escape.
Crossfeed Valve (900 CONFIG) - Allows
fuel flow from one booster pump to both A shutoff valve in the pump housing assembly
engines in case of a single booster pump is manually closed during removal of the pump
failure. cartridge assembly. The shutoff valve controls
fuel flow through the housing to the pump
NOTE: (900 CONFIG - PW207E) The cross cartridge assembly.
feed system, boost pump outlet check
valves, crossfeed valves, CROSS FEED (900 CONFIG - PW206A) - A replaceable
switch and system hoses are removed when fuel supply in-line check valve is located in the
upgraded from PW206A to PW207E . fuel supply outlet of each booster pump
housing assembly. The check valve prevents
Fuel Transfer System (902 CONFIG) - fuel from back flowing through a failed booster
Transfers fuel to the opposite side of the fuel pump.
cell longitudinal baffle whenever the booster
pumps are operating. Each booster pump is explosion proof. If fuel
vapors in the DC motor ignite, the flame is
A. Fuel Booster Pumps quenched as it tries to pass through the fuel
passages in the pump housing assembly.
The helicopter is equipped with two sub
merged, electrically driven booster pumps The booster pump fuel delivery volume at sea
bolted to the sump plate in the fuel cell. The level is 850 lbs/hr, nominal at 13.4 psi,
pumps provide pressurized fuel to the engines. minimum at 75F. Delivery at 20,000 feet is
Each booster pump is a single stage centrifu 400 lbs/hr, nominal at 6.5 psi, minimum at
gal pump driven by a 24 - 28 vdc, 4.5 ampere, 110F. The booster pumps are controlled by
negative ground motor. Each booster pump is individual switches on the center console.
composed of two major components; the pump B. Fuel Supply Lines
housing assembly and the pump cartridge
assembly. The pump cartridge assembly Self-sealing break-away frangible valve
houses the dc motor and impeller. The pump connections and fittings prevent loss of fuel
cartridge assembly is replaceable and can be from the fuel lines and fuel cell in the event of
removed from the helicopter without defueling. a hard landing.
Pump Cartridge Assembly - The pump The frangible valve connectors are located in
cartridge assembly is a radial type impeller the fuel lines that exit the fuel cell. Frangible
which separates expanding vapors from the valves are also located in the fuel fittings
fuel supply. Two bleed holes located in the mounted on main transmission deck.
Page 3
When tensile, shear, or bending loads are interrupt motor power and illuminate a valve
applied to the fuel supply line connectors and position indicator lamp on the IIDS display.
fittings, the frangible valve section breaks,
allowing the two halves of the coupling to Fuel Crossfeed Valve (900 CONFIG -
separate and seal the fuel passages. Once the PW206A) The fuel crossfeed/shutoff valve is a
frangible valve closure has occurred, a detent 28 vdc, two position motor actuated valve. The
moves into position and prevents the valve valve is normally closed, and is controlled by a
from reopening. An indicator is visible around pilot activated switch on the fuel system
the frangible connector when the valve is control panel. The valve has 2 limit switches
closed. that stop the travel and 2 position indicator
switches that complete an electrical circuit to
The fuel supply lines from the fuel cell to the illuminate a valve position light on the IIDS
main transmission deck are shrouded and display. The valve allows both engines to be
connected to a drain line to vent leaking fuel. fueled by the same or alternate booster pump.
In the event of a failed booster pump, the
C. Fuel Pressure Switch crossfeed valve is opened allowing the operat
The fuel pressure switch is a diaphragm type ing booster pump to supply fuel to both
normally closed switch. engines. The valve consists of an actuator and
valve body. The valve body consists of an
When measured fuel pressure is less than 3 aluminum alloy body, an aluminum alloy ball,
psig, the switch closes sending a signal to the support fittings, thermal relief assembly, seals,
IIDS display. The fuel flow bar indicator mounting bracket and associated hardware.
segments illuminate when fuel pressure is 3
psig or less. The actuator consists of an electric motor, gear
train, electrical magnetic interference (EMI)
D. Fuel Shutoff / Crossfeed filtering, limit switches, and electrical connec
tor. The limit switches are positioned near
Fuel Shutoff Valves - The engine fuel each end of the actuator's rotational travel to
shutoff valves are used to perform emergency interrupt motor power and illuminate a valve
shut down of the engines. The fuel shutoff position indicator lamp on the IIDS display.
valve is a 28 vdc, two position motor actuated
valve. The valve is normally open, and is The fuel flow bar indicator on the IIDS display
controlled by a pilot activated switch on the illuminates crossfeed valve positions. The
fuel system control panel. The valve has 2 crossfeed valve is shown in the open position
limit switches that stop the travel and 2 when the bar of the crossfeed indicator
position indicator switches that complete an segment is illuminated. Each of the valve
electrical circuit to illuminate a valve position indicator segments will flash when the valve is
light on the IIDS display. The fuel flow bar in between an open or closed position.
indicator on the IIDS display illuminates
shutoff valve positions. Each engine shutoff The fuel shutoff/crossfeed valves are shrouded
valve is shown in the open position when the and connected to the shrouded fuel supply
upper bar of each shutoff valve indicator lines to vent leaking fuel.
segment is not illuminated. The upper bar of E. Fuel Transfer System (902 CONFIG)
each indicator segment is illuminated when
the valve is closed. The fuel transfer system is designed to
equalize the fuel in the left and right fuel
The valve consists of an actuator and valve cavities and minimize unusable fuel.
body. The valve body consists of an aluminum
alloy body, aluminum alloy ball, support When either electric booster pump is operat
fittings, thermal relief assembly, seals, ing, fuel is pumped through a jet pump in the
mounting bracket and associated hardware. opposite fuel cell cavity. The jet pump draws
The actuator consists of an electric motor, gear fuel from the sump through a pickup and the
train, electrical magnetic interference (EMI) fuel is ejected on the other side of the longitu
filtering, limit switches, and electrical connec dinal baffle. For example, when the left
tor. The limit switches are positioned near booster pump is operating, fuel is transferred
each end of the actuator's rotational travel to to the left fuel cell cavity.
Page 4
FUEL SUPPLY SYSTEM

FRANGIBLE VALVE (2 PL)
FUEL SHUT-OFF
VALVE (2 PL)
AFT FUEL VENT

STANDPIPE
RIGHT ENGINE
FEED TUBE ASSY LEFT ENGINE
FEED TUBE ASSY
DUAL VENT/ROLLOVER
VALVE (2 PL)
SINGLE VENT/ROLLOVER
VALVE (2 PL)
AFT FUEL
PROBE
FUEL
FILLER
TEE FITTING
(2 PL)
GRAVITY SELF SEALING
FILL PORT FRANGIBLE VALVE (2 PL)
FUEL NOTE
CELL
HOSE ASSY
RIGHT
SUMP DRAIN
CONTROLS (2 PL) FUEL BOOSTER HOSE ASSY
FWD FUEL PUMP (2 PL) LEFT
PROBE
FORWARD FUEL FUEL PRESSURE

VENT STANDPIPE SWITCH ASSY (2 PL)
FUEL CROSSFEED
SHUT-OFF VALVE ASSY
NOTE:
FUEL CROSSFEED SYSTEM REMOVED ON 900 CONFIG HELICOPTERS CONVERTED TO PW207E ENGINES.
9G28-002C
Figure 1. Fuel System (900 CONFIG)
Page 5
ENGINE DECK
FRANGIBLE VALVE (2 PL)
FUEL SHUTOFF
VALVE (2 PL)
RIGHT ENGINE
FEED TUBE ASSY
LEFT ENGINE
FEED TUBE ASSY
AFT FUEL VENT

STANDPIPE
DUAL VENT/
ROLLOVER VALVE
SINGLE VENT/ROLLOVER
VALVE ( 2 PL)
SELF SEALING
FUEL FILLER
FRANGIBLE VALVE
(2 PL)
TEE FITTING
(2 PL)
FUEL CELL AFT FUEL PROBE
SUMP DRAIN
CONTROLS (2 PL) FUEL BOOSTER
PUMP (2 PL)
FORWARD FUEL PROBE JET PUMP (2 PL)
FUEL VENT CHECK VALVE (2 PL)

STANDPIPE
9G28-048
Figure 2. Fuel System (902 CONFIG)
Page 6
Original 28-00-00
VIEW LOOKING AFT

RIGHT LEFT
FUEL SHUTOFF ENGINE ENGINE
ENGINE DECK
VALVE (2 PL) FRANGIBLE
CONNECTOR (2 PL)
NOTE 2. NOTE 1.
FUEL PRESSURE FMU SHROUD CROSSFEED VALVE
SWITCH (2 PL) BOX (2 PL) VAPOR SHROUD
OVRBD DRAIN INTERCONNECT FITTING
VAPOR SHROUD DRAIN (2 PL)
(TO ENGINE DRAIN SYS)
TO FWD RH M M M
VENT SYS TO AFT LH
VENT SYS
RH FUEL
FUEL CELL
FEED SYS VENT ROLLOVER
BAFFLE (2 PL)
VALVE (4 PL)
FUEL FILLER RH FWD LH

ASSY FUEL FEED VENT SYS
VAPOR SHROUD
LH FUEL
FEED
GRAVITY VAPOR
FLAME FUEL CELL SHROUD
ARRESTOR FILL
(2 PL) VALVE LH FUEL
FEED SYS
FUEL FEED
FRANGIBLE
CONNECTOR (2)
VENT OVBD
DRAIN (2 PL) FUEL CELL OUTLET
VAPOR SHROUD
FUEL BOOST CHECK VALVE DRAIN (2 PL)
SUMP PUMP (2 PL) (2 PL)
DRAIN NOTE
CABLE
SUMP OVBD FUEL QTY PROBE (2 PL) SUMP DRAIN
DRAIN (2 PL) LOW LEVEL INDICATOR VALVE (2 PL)
ON AFT PROBE
NOTES:
1. FUEL CROSSFEED SYSTEM REMOVED ON 900 CONFIG HELICOPTERS CONVERTED TO PW207E ENGINES.
2. FMU SHROUD BOX INSTALLED ON 900 CONFIG HELICOPTERS CONVERTED TO PW207E ENGINES.
9G28-001A
Figure 3. Fuel System Schematic (900 CONFIG)
Page 7
VIEW LOOKING AFT
RIGHT LEFT
ENGINE ENGINE
FUEL METERING UNIT (FMU) ENGINE DECK FRANGIBLE
SHROUD BOX (2 PL) CONNECTOR (2 PL)
FUEL SHUTOFF TEE FITTING VAPOR

VALVE (2 PL) ENGINE DECK SHROUD DRAIN (2 PL) TO
ENGINE DRAIN SYSTEM
FUEL PRESSURE
SWITCH (2 PL) TEE FITTING (2 PL) VENT/ROLLOVER
RH FUEL FEED SYS VALVE (4 PL)
RH FUEL FEED TO AFT LH
VAPOR VENT SYS
TO FWD RH
VENT SYS SHROUD
SPRING LOADED
FLAPPER VALVE
FUEL FILLER FWD LH
ASSY VENT SYS
FLAME GRAVITY FILL VALVE LH FUEL FEED

ARRESTOR (2 PL) AND FLAPPER VALVE VAPOR SHROUD
VENT OVBD LH FUEL

DRAIN (2 PL) FEED SYS
FUEL FEED
FRANGIBLE
SUMP DRAIN
CONNECTOR (2 PL)
CONTROL CABLE
FUEL BOOST SUMP OVBD LOW FUEL LEVEL
DRAIN (2 PL) FUEL CELL OUTLET
PUMP (2 PL) SUMP DRAIN SENSOR (2 PL) VAPOR SHROUD
VALVE (2 PL) FUEL CELL
FUEL QTY PROBE
(2 PL) LEFT AND RIGHT CENTER
BAFFLE
FUEL BOOST
PUMP (2 PL) CENTER BAFFLE
FEED SUPPLY TO RIGHT ENGINE FUEL SUPPLY TO LEFT ENGINE
JET PUMP (2 PL)

TEE FITTING (2 PL)
CHECK VALVE (2 PL)
RH FUEL TRANSFER TUBING LOOKING DOWN LH FUEL TRANSFER TUBING
FUEL TRANSFER SYSTEM
9G28-049
Figure 4. Fuel System Schematic (902 CONFIG)
Page 8
Original 28-00-00
FUEL SYSTEM
FAULT ISOLATION
1. Fuel System Troubleshooting The troubleshooting tables should be used
with the simplified system schematics,
electrical wiring diagrams, serv nability checks
(Ref. Figure 101 thru Figure 106) and other detailed procedures in this and other
chapters of the manual.
brief summary of fuel system faults which may in the Rotorcraft Maintenance Manual
be encountered (Ref. Table 101). CSP-900RMM-3 (Ref. Section 98-40-00).
Table 101. Fuel System Troubleshooting
LOW OR NO FUEL
PRESSURE (900 CONFIG)
FUEL low fuel pressure Set CROSSFEED valve
caution segments illuminated switch to ON (open) position
on IIDS panel with boost ON. and turn opposite side
booster pump ON;
If low fuel pressure remains Replace fuel pressure switch. 280000
illuminated:
Faulty fuel pressure switch.
Disconnected or ruptured Verify fuel supply lines security 280000
fuel supply line in fuel cell. and condition. Repair or
replace parts as required.
Faulty wiring between fuel Test and repair wiring. 206000
pressure switch and IIDS.
FUEL low fuel pressure Troubleshoot fuel crossfeed Replace fuel crossfeed system 280000
caution segments illuminated system valve and hose. valve or hose.
on IIDS panel with boost ON.
If low fuel pressure light
goes off:
Faulty fuel booster pump. Replace fuel booster pump 280000
cannister.
Faulty fuel booster pump Test and repair wiring. 206000
wiring.
Contaminated fuel. Perform Contaminated Fuel 280000
Cell Procedure.
Fuel cell frangible valve Check frangible valve indicators 280000
closed off fuel supply. for closure.
Page 101
Table 101. Fuel System Troubleshooting (Cont.)

LOW OR NO FUEL
PRESSURE (902 CONFIG)
FUEL low fuel pressure Faulty fuel booster pump. Replace fuel booster pump 280000
caution segments illuminated cannister.
on IIDS panel with boost ON.
Faulty fuel booster pump Test and repair wiring. 206000
wiring.
Faulty fuel pressure switch. Replace fuel pressure switch. 280000
Faulty fuel pressure switch Test and repair wiring. 206000
wiring.
Disconnected or ruptured Replace fuel supply line. 280000
fuel supply line in fuel cell.
Contaminated fuel. Perform Contaminated Fuel 280000
Cell Procedure.
Fuel cell frangible valve Check frangible valve indicators 280000
closed off fuel supply. for closure.
FUEL impending bypass Clogged engine fuel filters. Replace engine fuel filters. 010000
caution segments illuminated Bench check fuel filter caution
on IIDS panel. light pressure switch.Refer to
Related Manufacturers
Publications Table 201.
Contaminated fuel. Perform the Contaminated Fuel 280000
Cell Procedure.
Faulty fuel filter pressure Replace differential pressure 010000
differential switch. switch. Refer to Related
Manufacturers Publications
Table 201.
Fuel sump sample shows Contaminated fuel. Perform the Contaminated Fuel 280000
contamination. Cell Procedure.
Page 102

Bottom of fuselage stays wet Fuel drain valves not Rotate push knob on fuel drain 280000
with fuel. returning to closed position. cable clockwise until a
resistance is felt. Then rotate
knob counterclockwise (less
than one full turn) until label on
knob is upright. Push in and
release 2 to 3 times to verify
correct operation.
Fuel drain valves not Replace drain valve. 280000

returning to closed position.
Drain valve control cable Replace control cable. 280000
kinked or binding not
allowing drain valves to
return to closed position.
Fuel leaking past Orings of Replace Orings. 280000
booster pump or pump
canister.
Fuel leaking past Oring of Replace Oring. 280000
pump drain plug.
Fuel leaking past Oring of Replace Oring. 280000
fuel quantity probe.
Loose or broken fuel cell Inspect and repair or replace as 280000
attachment fittings. required.
Fuel cell leak. Pressure test, remove and 280000
repair, or replace cell as
required.
FUEL QUANTITY
INDICATION ERRORS
FUEL low level warning(s) Faulty fuel quantity Remove, test, calibrate or 280000
illuminated with known transmitter probes. replace fuel quantity probes.
quantity above 160 lbs in
cruise or 220 lbs in hover. Faulty fuel transfer system. Perform Fuel Transfer System 280000
(902 CONFIG) Operational Test
Repair faulty component.
Contaminated fuel. Perform the Contaminated Fuel 280000
Cell Procedure.
FUEL low level warning(s) Faulty aft fuel quantity Remove, test, calibrate or 280000
illuminated with known probe. replace aft fuel quantity probe.
quantity above 300 lbs. (900 Thermistor not set to a
CONFIG) proper level on fuel quantity
probe.
Page 103

FUEL low level warning Faulty aft fuel quantity probe Remove, test, calibrate or 280000
segments not illuminated with (900 CONFIG). replace aft fuel quantity probe.
fuel quantity known below Thermistor not set to a
125 lbs. proper level on fuel quantity
probe.
Faulty wiring circuit between Test and repair wiring circuit. 206000
fuel quantity probe and 280000
circuit breaker.
fuel quantity probe and IIDS. 280000
Faulty left or right fuel Remove, test, calibrate or 280000
quantity probe replace left or right fuel quantity
(902 CONFIG). probe.
SENSFALT=4 On IIDS Faulty forward (left) fuel Replace forward (left) fuel 280000
alpha/numerical display. quantity probe. (Out of range probe.
high or low.)
SENSFALT=5 On IIDS Faulty aft (right) fuel quantity Replace aft (right) fuel probe. 280000
alpha/numerical display. probe.
FUEL quantity LB digital Loose or faulty wiring or Inspect, test and repair wiring. 206000
display readout does not connections on fuel quantity
match actual known fuel transmitter probes.
quantity.
Faulty forward or aft (left or Remove, test, calibrate or 280000
right) fuel quantity replace forward and aft (left
transmitter probe and right) fuel quantity
transmitter probes.
Incorrect fuel calibration Enter correct factors, if known, 280000
factors in IIDS or perform fuel calibration.
FUEL quantity LB digital Faulty forward or aft (left or Remove, test, calibrate and 280000
display readout not right) fuel quantity repair or replace transmitter
illuminated with approximate- transmitter probe. Refer to probe.
ly half of known FUEL IIDS alphanumeric fault
quantity segments shown. display.
FUEL quantity segment bars Loose or faulty IIDS battery Test and repair wiring. 206000
not illuminated on IIDS with bus voltage sensor wiring. 280000
FUEL quantity LB digital
display showing correct Battery voltage low, below Refer to IIDS alphanumerical 961000
known fuel quantity. 19.0 volts. fault display.
Do not attempt an engine
start with battery.
Page 104

FUEL crossfeed valve (900 Faulty crossfeed shutoff Replace crossfeed shutoff 280000
CONFIG)segment continues valve internal components valve.
to flash on IIDS, switch in ON indicating valve stuck
position. between (open and close)
positions.
Faulty wiring between circuit Test and repair wiring. 206000
breaker, crossfeed shutoff 280000
valve and IIDS panel.
FUEL shutoff valve Faulty fuel shutoff valve Replace fuel shutoff valve. 280000
segments continue to flash (limit switches).
on IIDS panel indicating
shutoff valve stuck between Faulty wiring between circuit Test and repair wiring. 206000
(open and close) positions. breaker, fuel shutoff valve
and IIDS panel.
A2 A612 A115
IIDS FWD INTERCONNECT PANEL LH FUEL PRESSURE SWITCH
W122 W125
J5 P105 P170 J3 J2 P173 P351 J1
LEFT FUEL PRESS LOW Y 5 16 A
GS305-J E B
A114
W123 RH FUEL PRESSURE SWITCH
W124
J4 P104 P171 J1 J6 P172 P350 J1
RIGHT FUEL PRESS LOW X 5 15 A
GS306-J E B
9G28-030A
Figure 101. Fuel Pressure Switch Wiring Diagram
A620 A604
ELECTRICAL LOAD CENTER ENGINE/FUEL CONTROL PANEL
S5 A112
W124 W128 RH FUEL BOOST PUMP
CB4 W124 R FUEL BOOST
R BST PMP J2 P124 P122 J122
J6 P378 P124 J2 SWITCH
3 ON
2 W B1 +
10A C Z GS131 E -
1 OFF
S3 W125 W127
A111
CB5 W125 L FUEL BOOST LH FUEL BOOST PUMP
L BST PMP J5 P379 P130 J1 SWITCH J1 P130 P119 J119
3 ON
2 W B1 +
10A C Z
GS130 E -
1 OFF
9G28-029A
Figure 102. Fuel Boost Pump Wiring Diagram
Page 105
PERMANENT MAGNET FIELD THERMAL PROTECTOR

(NON-RESETABLE)
+ BLACK
- WHITE
FUSE
INTERNAL GND 9G28-032A
Figure 103. Fuel Boost Pump Wiring Schematic
A612
FWD INTERCONNECT
A2 PANEL A107
IIDS AFT FUEL PROBE
W122 W124 W128
J3 P103 P122 J122
P170 J3 J6 P172 J223 P1
P P P
P P P P P
FUEL PROBE AFT HI 23 25 25 A1 D FUEL PROBE AFT HI
FUEL PROBE AFT LO 24 26 26 A2 C FUEL PROBE AFT LO
A8
FUEL LOW DISCRETE 62 28 28 A3 H FUEL LOW DISCRETE

P A 28VDC
J2 P102 W123 B PWR RTN
P171 J1 J2 P173 P
P P P F LOW FUEL 28VDC
P P
FUEL PROBE FWD HI 23 23 23 G PWR RTN
FUEL PROBE FWD LO 24 24 24
A104
W125 W127 FWD FUEL PROBE
P119 J119 J222 P1
P P P
A601 A1 D FUEL PROBE FWD HI
CIRCUIT BREAKER PANEL A2 C FUEL PROBE FWD LO
J1 P131 A8
6 A4 P P A 28VDC
GS105-G E A5 B PWR RTN
CB14
A620 FUEL PROBE
J2 P128 P122 J122
ELECTRICAL LOAD CENTER W124
P
5A 9 A4
CB1
FUEL LOW
J2 P374 GS106-G E A5
W124 P
5A 6 A6
GS106-H E A7
9G28-027A
Figure 104. Fuel Quantity Gauging Probes Wiring Diagram (900 CONFIG)
Page 106
Original 28-00-00
A612
FWD INTERCONNECT
A2 PANEL A104
IIDS RIGHT FUEL PROBE
W122 W124 W128
J3 P103 P122 J122
P170 J3 J6 P172 J223 P1
P P P
P P P P P
FUEL PROBE RIGHT HI 23 25 25 A1 D FUEL PROBE RIGHT HI
FUEL PROBE RIGHT LO 24 26 26 A2 C FUEL PROBE RIGHT LO
E
A8
RIGHT FUEL
RIGHT FUEL 62 28 28 A3 H LOW DISCRETE
LOW DISCRETE P A 28VDC
J2 P102 W123 W125 B PWR RTN
P171 J1 J2 P173 P
P P P F LOW FUEL 28VDC
P P
FUEL PROBE LEFT HI 23 23 23 G 28 VDC RTN
FUEL PROBE LEFT LO 24 24 24
J5 P105 P170 J3
W122
LEFT FUEL LOW V 1 14
DISCRETE
A107
W127 LEFT FUEL PROBE
P119 J119 J222 P1
P P
A601 A1 4 FUEL PROBE LEFT HI
CIRCUIT BREAKER PANEL A2 3 FUEL PROBE LEFT LO
5
J1 P131 A8 8 LEFT FUEL LOW
DISCRETE
6 A4 P 1 28VDC IN
GS105-G E A5 2 28 VDC RTN
CB22
FUEL PROBE J2 P128 A3
A6 6 LOW FUEL 28 VDC IN
5A 9
LH ESS BUS GS104-F E A7 7 28 VDC RTN
W124 P122 J122

A620 P
CB1 J2 P374 GS106-G E A5

W124
P
6 A6
5A
BAT BUS GS106-H E A7
CB41 J1 P375
W125
6
5A
BAT BUS
9G28-057B
Figure 105. Fuel Quantity Gauging Probes Wiring Diagram (902 CONFIG)
Page 107
A104 A107
FWD FUEL PROBE AFT FUEL PROBE
P1 P1
0.2 - 5.0V DIFFERENTIAL FUEL 0.2 - 5.0V DIFFERENTIAL FUEL
HI D HI D
LO QUANTITY SIGNAL QUANTITY SIGNAL
C P LO C
E R E P
O R
28VDC B 100 mA LOW LEVEL DISCRETE O
A H
PWR RTN E A 28VDC B
B
PWR RTN E
B
LOW FUEL 28 VDC
LOW LEVEL F
DETECTOR PWR RTN
G
9G28-034A
Figure 106. Fuel Quantity Probes Schematic (900 CONFIG)

A107 A104
LEFT FUEL PROBE RIGHT FUEL PROBE
P1 P1
0.2 - 5.0V DIFFERENTIAL FUEL 0.2 - 5.0V DIFFERENTIAL FUEL
HI 4 HI D
LO QUANTITY SIGNAL LO QUANTITY SIGNAL
3 C
5 E P
P R
100 mA LOW LEVEL DISCRETE R 100 mA LOW LEVEL DISCRETE O
8 H
28VDC
O 28VDC B
1 A
B E
PWR RTN PWR RTN
2 E B
LOW FUEL 28 VDC LOW FUEL 28 VDC
LOW LEVEL 6 LOW LEVEL F
DETECTOR PWR RTN DETECTOR PWR RTN
7 G
9G28-059A
Figure 107. Fuel Quantity Probes Schematic (902 CONFIG)
Page 108
A604 A119
A601 ENGINE/FUEL CONTROL PANEL FUEL SHUTOFF VALVE
S4 (CROSSFEED)
CB8
XFD VLV W125 FUEL CROSSFEED W125 P355 J1
SWITCH 1 J1 P130
J1 P131 P130 J1 CLOSED
G A
2
5A 3 E
OPEN
F H
3 W126
GS303-C E F
M
GS305-K E D
GS307-H E G
C
SH2 A
E
A117
LH FUEL SHUTOFF VALVE
CB7 S6
L FUEL BOOST W125 P353 J1
L FUEL VLV
SWITCH 1 CLOSED
U A
2
5A 4 X
OPEN
V H
3
4 GS301-B E F
5 SEL
M
GS303-A E D
6
GS303-B E G
E
SH2 B
C
A116
S7 RH FUEL SHUTOFF VALVE
CB12 W124 R FUEL BOOST
R FUEL VLV J2 P124 W124 P352 J1
J2 SWITCH
P129 P124 J2 1 CLOSED
U A
2
5A 5 X 3 OPEN
V H
E Y E 4 SEL
GS302-E E F
GS100-K 5 M
GS302-F E D
6
GS304-C E G
E
SH2 C
C
9G28-028-1A
Figure 108. Fuel ShutOff and Crossfeed Valve Wiring Diagram (900 CONFIG PW206A)
(Sheet 1 of 2)
Page 109
A2 A612
IIDS FWD INTERCONNECT PANEL
W122 W125
J5 P105 P170 J3 J2 P173
FUEL XFEED VALVE CLOSED V 1 14 A SH1
FUEL XFEED VALVE OPEN U 2 15
RIGHT FUEL VALVE OPEN W 3

RIGHT FUEL VALVE CLOSED X 4
J4 P104 W123 P171 J1

LEFT FUEL VALVE OPEN V 3 17 B SH1
LEFT FUEL VALVE CLOSED W 4 18
J6 P172
13 C SH1
14
9G28-028-2A
Figure 108. Fuel ShutOff and Crossfeed Valve Wiring Diagram (900 CONFIG PW206A)
(Sheet 2 of 2)
Page 110
A601 A604
CIRCUIT BREAKER PANEL ENGINE/FUEL CONTROL PANEL
W125
A117
LH FUEL SHUTOFF VALVE
CB7 S6 W125
L FUEL SHUTOFF J1 P130 P353 J1
L FUEL VLV P130 J1
J1 P131 SWITCH 1 CLOSED
U A
2
5A 4 X
OPEN
V H
3
4 GS301-B E F
5 SEL
M
GS303-A E D
6
GS303-B E G
E
SH2 B
C
A116
S7 RH FUEL SHUTOFF VALVE
CB12 W124 R FUEL SHUTOFF
R FUEL VLV J2 P124 W124 P352 J1
J2 P128 SWITCH
P124 J2 1 CLOSED
U A
2
5A 5 X 3 OPEN
V H
E Y E 4 SEL
GS302-E E F
GS100-K 5 M
GS302-F E D
6
GS304-C E G
E
SH2 A
C
9G28-060-1A
Figure 109. Fuel ShutOff Valve Wiring Diagram (902 CONFIG, 900 CONFIG PW207E)
(Sheet 1 of 2)
Page 111
A2 A612
IIDS FWD INTERCONNECT PANEL
W122 W125
J5 P105 P170 J3 J2 P173
RIGHT FUEL VALVE OPEN W 3

RIGHT FUEL VALVE CLOSED X 4
J4 P104 W123 P171 J1

LEFT FUEL VALVE OPEN V 3 17 B SH1
LEFT FUEL VALVE CLOSED W 4 18
W124
J6 P172
13 A SH1
14
9G28-060-2
Figure 109. Fuel ShutOff Valve Wiring Diagram (902 CONFIG, 900 CONFIG PW207E)
(Sheet 2 of 2)
CLOSE INDICATOR CLOSE COMMON OPEN OPEN INDICATOR
SHUTOFF VALVE SHOWN IN MID POSITION (DE-ENERGIZED)

9G28-031A
Figure 110. Fuel ShutOff Valves / Crossfeed Valve Wiring Schematic (Typical)
Page 112
FUEL SYSTEM
1. Fuel Cell (3). Remove cabin seats, if applicable
(Ref. 25-20-00, Cabin Seat Assembly
A. General Removal).
(4). Remove carpet, if applicable (Ref.
CAUTION 25-20-00, Cabin Carpet Removal).
AMFUEL cells removed from service (5). Remove cabin floor panels AL165,
must not be left dry for more than 10 AR165 and A170 (Ref. 53-20-00, Cabin
days. Do not allow the cell to be in direct Floor Outboard Panel Removal and
sunlight for extended periods. Apply Cabin Floor Center Panel Removal).
SAE10 oil as a plasticizing agent. The cell
liner will lose pliability if left dry for ex (6). Remove fuel cell access covers (Ref.
tended periods. Subsequent flexing may 28-00-00, Fuel Cell Access Cover
cause material to crack. Removal).
Fuel cells are susceptible to fungus (7). Remove check valves and jet pumps
growth after contact with contaminated (Ref. 28-00-00, Fuel Cell Removal).
fuel. Fungus trapped in the fuel filters in
dicates fuel tank contamination. Remove, (8). Remove fuel transfer in-line check
inspect, clean or replace filter elements valves in accordance with instructions
per applicable Pratt & Whitney Mainte in Fuel Cell Removal
nance Manual. (Ref. 28-00-00)
NOTE: Periodic incorporation of an FAA/CAA/ (9). Inspect the check valve.

JAA approved anti-fungal fuel additive will (a). Rinse the check valve in isopropyl
kill and prevent new fungus growth. alcohol. Let air dry.
B. Contaminated Fuel Cell Procedure (b). Apply air pressure to outlet port to
(902 CONFIG) verify check valve is in the closed
position. There should be no flow.
Aviation Turbine Fuel Perform In-Line Check Valve
Disassembly/Assembly or discard
check valve if there is flow.
(c). Attempt to manually open the check
valve by inserting a 0.16 inch diame
NOTE: If allowable serviceability criteria is ex ter or smaller rod. Insert rod into the
ceeded, contact MDHI Field Service Depart inlet port of the check valve and
ment for disposition. apply light axial pressure. The check
valve poppet should freely open
Consumable Materials under light force and close when the
(Ref. CSPSPM) force is released. Perform In-Line
Item Nomenclature Check Valve Disassembly/Assembly
or discard check valve if the poppet
C419 Alcohol, Isopropyl does not freely move.
(10). Perform In-Line Check Valve Disas
(1). Defuel helicopter (Ref. 12-00-00, sembly/Assembly or discard Check
Defueling). Valve.
(2). Drain all remaining fuel from fuel sump (11). Verify that each jet pump nozzle is clear
drains. (open). Clean if clogged.
Page 201
(12). Flush out the jet pump supply tubes. (23). Inspect fuel supply hose clamps for
security and deterioration. Repair or
(13). Flush out engine fuel supply lines. replace as required.
(14). Clean fuel booster pump inlet screens. (24). Inspect fuel quantity probes for
security.
CAUTION The orange umbrella shaped (25). Inspect the engine fuel filter elements
check valves are easily damaged. No dam (Ref. Pratt & Whitney Maintenance
age to the umbrella check valves is allowed. Manual). Replace as required.
(26). Install fuel transfer in-line check
(15). On the fuel booster pump, ensure the valves in accordance with instructions
holes under the two orange umbrella in Fuel Cell Removal (Ref. 28-00-00)
check valves are not clogged.
(27). Install fuel cell access covers (Ref.
(a). Clean if clogged. It may be necessary 28-00-00, Fuel Cell Access Cover
to replace the booster pump if the Installation).
holes cannot be unclogged.
(28). Install cabin floor panels AL165,
Alcohol, Isopropyl (C419) AR165 and A170 (Ref. 53-20-00, Cabin
Floor Outboard Panel Installation and
Cabin Floor Center Panel Installation).
(29). Perform fuel cell check/pressure test
(Ref. 28-00-00, Fuel Cell Check/Pres
(16). Clean all internal fuel cell surfaces with sure Test).
lint free cloth moistened with isopropyl
(30). Add 10 gallons (38 Liters) of fuel to
alcohol to remove foreign object
helicopter (Ref. 12-00-00, Main Fuel
contamination. Air dry for 15 minutes.
Tank Fueling). Wait one hour after
(17). Install jet pumps and check valves (Ref. fueling before you proceed.
28-00-00, Fuel Cell Installation). (31). Check for fuel contamination.
(18). Inspect fuel cell baffles for security and (a). Obtain fuel samples from both fuel
flapper valve for freedom of movement. sump drains and examine samples
for evidence of contamination.
(19). Inspect fuel cell baffle lacing cord for
fraying or loose fibers. Replace if (b). If evidence of fuel contamination is
required. found, repeat Contaminated Fuel
Cell Procedures until no contamina
(20). Inspect fuel cell longitudinal baffle for tion exists.
debonding where the metal baffle
(32). Install carpet, if applicable (Ref.
connects to the rubber. None allowed.
25-20-00, Cabin Carpet Installation).
(21). Inspect fuel cell frangible valves for (33). Install cabin seats, if applicable (Ref.
security. 25-20-00, Cabin Seat Assembly
Installation).
(22). Inspect fuel supply hoses for deteriora
tion, collapsed or kinked hoses. No (34). Fuel helicopter (Ref. 12-00-00, Main
damage allowed. Fuel Tank Fueling).
Page 202
C. Contaminated Fuel Cell Procedure Alcohol, Isopropyl (C419)

(900 CONFIG)
(10). Clean all internal fuel cell surfaces with

lint free cloth moistened with isopropyl
alcohol to remove foreign object
NOTE: If allowable serviceability criteria is ex contamination. Air dry for 15 minutes.
ceeded, contact MDHI Field Service Depart
ment for disposition. (11). Inspect fuel cell baffles for security and
flapper valves for freedom of move
ment.
(Ref. CSPSPM) (12). Inspect fuel cell baffle lacing cord for
Item Nomenclature fraying or loose fibers. Replace if
required.
(13). Inspect fuel cell longitudinal baffle for
debonding where the metal baffle
(1). Defuel helicopter (Ref. 12-00-00, connects to the rubber. None allowed.
Defueling).
(14). Inspect fuel cell frangible valves for
(2). Drain all remaining fuel from fuel sump security.
drains.
(15). Inspect fuel supply hoses for deteriora
(3). Remove cabin seats, if applicable (Ref. tion, collapsed or kinked hoses. No
25-20-00, Cabin Seat Assembly damage allowed.
Removal).
(16). Inspect fuel supply hose clamps for
(4). Remove carpet, if applicable (Ref. security and deterioration. Repair or
25-20-00, Cabin Carpet Removal). replace as required.
(5). Remove cabin floor panels AL165, (17). Inspect fuel quantity probes for
AR165 and A170 (Ref. 53-20-00, Cabin security.
Floor Outboard Panel Removal and
(18). Inspect the engine fuel filter elements
Cabin Floor Center Panel Removal).
(Ref. Pratt & Whitney Maintenance
(6). Remove fuel cell access covers (Ref. Manual). Replace as required.
28-00-00, Fuel Cell Access Cover (19). Install fuel cell access covers (Ref.
Removal). 28-00-00, Fuel Cell Access Cover
(7). Flush out engine fuel supply lines. Installation).
(8). Clean fuel booster pump inlet screens. AR165 and A170 (Ref. 53-20-00, Cabin
Floor Outboard Panel Installation and
CAUTION The orange umbrella shaped Cabin Floor Center Panel Installation).
check valves are easily damaged. No dam (21). Perform fuel cell check/pressure test
age to the umbrella check valves is allowed. (Ref. 28-00-00, Fuel Cell Check/Pres
sure Test).
(9). On the fuel booster pump, ensure the
holes under the two orange umbrella (22). Add 10 gallons (38 Liters) of fuel to
check valves are not clogged. helicopter (Ref. 12-00-00, Main Fuel
Tank Fueling). Wait one hour after
(a). Clean if clogged. It may be necessary fueling before you proceed.
to replace the booster pump if the
holes cannot be unclogged. (23). Check for fuel contamination.
Page 203
(a). Obtain fuel samples from both fuel (24). Install carpet, if applicable (Ref.
sump drains and examine samples 25-20-00, Cabin Carpet Installation).
for evidence of contamination.
(25). Install cabin seats, if applicable (Ref.
25-20-00, Cabin Seat Assembly
(b). If evidence of fuel contamination is Installation).
found, repeat Contaminated Fuel
Cell Procedures until no contamina (26). Fuel helicopter (Ref. 12-00-00, Main
tion exists. Fuel Tank Fueling).
Page 204
FUEL SYSTEM
1. Fuel Cell (12). Remove bolts (26) and washers (27).
A. Fuel Cell Removal (13). Remove sealant from bolt heads (23).
(Ref. Figure 401) (14). Remove bolts (23) and washers (24).
(15). Remove and discard o-ring (25).
(Ref. CSPSPM) (16). Disconnect booster pump wire har
Item Nomenclature nesses (10, Figure 403) as follows:
C707 Tape, Pressure Sensitive (a). Remove screw (16) from left booster
pump and disconnect A111 (Q12D16)
wire positive (+) terminal.
(b). Remove screw (16) from right booster
pump and disconnect A112 (Q13C16)
wire positive (+) terminal.
(c). Remove screw (17) from left booster
(1). Defuel helicopter (Ref. Section pump, push up on shut-off lever arm.
12-00-00). Remove A111 (Q35A16N) and
(2). If necessary, remove cabin seats (Ref. (Q35B16) wire from negative (-)
Section 25-20-00). terminal.
(3). If necessary, remove carpet (Ref. (d). Remove screw (17) from right booster
Section 25-20-00). pump, push up on shut-off lever arm.
Remove A112 (Q36A16N) and
(4). Remove panels AL155, AR155, A160, (Q36B16) wire from negative (-)
AL165, AR165, A170, A217, AL230, terminal.
(17). Disconnect forward and aft fuel sump
(5). Remove panel B178 (Ref. Section drain valve controls.
06-00-00).
System Contamination
CAUTION CAUTION
(6). Remove fuel cell access covers. Do not fold fuel cell in temperatures less
than 50 F (10 C).
(7). Remove forward and aft fuel quantity
probes. Do not use fuel cell metal fittings to lift or
move fuel cell. Damage to the barrier that
(8). Remove left and right fuel cell frangible you can not see can occur.
valves.
(19). Carefully remove fuel cell (1).
(9). Remove single and dual vent/rollover
NOTE: If fuel cell is to be replaced, do the steps
valves. that follow:
(10). Remove fuel filler neck flexible coupling (20). Remove fuel sump drain valves.
(8, Figure 407) and remove and discard
o-rings (7). (21). Remove fill port check valve.
(11). Remove sealant from bolt heads (26, (22). Remove screws (19), washers (20), and
Figure 401). clamps (21) from left and right inner
Page 401
side of fuel cell (1) and remove fuel

supply hoses (22). Special Tools
(Ref. CSPSPM)
(23). Remove centrifugal fuel booster pumps. Item Nomenclature
(24). 902 CONFIG - Remove fuel transfer T801 Fuel Cell Rod
system as follows:
(a). Disconnect left and right tubes (23, (1). Remove all unwanted material from
Figure 406). fuel cell space.
(b). Remove nuts (28), bolts (26), washers

NOTE: If fuel cell is new, do the steps that fol
low before you install fuel cell.
(27), and clamps (25) and remove
tubes. (2). Install fuel drain valves.
(c). Remove left and right tubes (24). (3). Install fuel supply hoses, clamps,
screws, and washers. Torque screws.
(d). Remove check valves (18) and
bushings (20). Discard packings (19, (4). Install centrifugal fuel booster pumps.
21).
(5). 902 CONFIG - Install fuel transfer
(e). Remove bolts (15), washers (17), system as follows.
clamps (14), spacers (16), and jet
pumps (22). (a). Prepare mating surfaces of fuel cell
base plate, brackets, jet pumps, and
(f). Remove bolts (12), washers (13), and check valves for electrical bond (Ref.
brackets (11). CSP-SPM).
(25). Apply pressure sensitive tape (C707) to (b). Install brackets, bolts, and washers.
all machined metal surfaces. Torque bolts.
B. Fuel Cell Installation (c). Install jet pumps, bolts, washers,

clamps, and spacers. Torque bolts.
(Ref. Figure 401)
(d). Install check valves and bushings
with new packings. Torque bushings
Consumable Materials and check valves.
(Ref. CSPSPM)
Item Nomenclature (e). Connect left and right tubes (24).
Torque tube nuts.
C109 Grease (f). Install clamps, bolts, washers, and
nuts. Torque nuts.
Page 402
(g). Install tubes on jet pumps. Torque (15). Install flexible coupling (8).
tube nuts.
(6). Install fill port check valve. (16). Install fuel cell frangible valves.
(17). Install single and dual vent/rollover

CAUTION
valves.
Do not fold fuel cell in temperatures less
than 50 F (10 C). (18). Install forward and aft fuel quantity
Do not use fuel cell metal fittings to lift or probes.
move fuel cell. Damage to the barrier that
you can not see can occur. (19). Connect forward and aft fuel sump
drain valve controls.
(7). Carefully put fuel cell in fuel cell space.
(8). Align attach points of fuel cell with keel (20). Connect booster pump wire harness
beam and opening in bottom of fuse (10, Ref. Figure 403) as follows:
lage.
(a). Install A111 (Q12D16) wire and
(9). Install bolts (28) and washers (29). screw to left booster pump positive
Torque bolts. (+) terminal. Torque screw.
Torque bolts. (b). Install A112 (Q13C16) wire and
screw to right booster pump positive
Sealing Compound (C207) (+) terminal. Torque screw.
(c). Push up on lever arm and install

wires A111 (Q35A16N) and
(Q35B16) and screw to left booster
(11). Environmentally seal bolt heads and pump negative (-) terminal. Make
washers, use sealing compound (C207) sure wires are between shoulder on
(Ref. CSP-SPM). screw and lever arm. Torque screw.
Torque bolts. (d). Push up on lever arm and install
wires A112 (Q36A16N) and
Sealing Compound (C207) (Q36B16) and screw to right booster
pump negative (-) terminal. Make
sure wires are between shoulder on
screw and lever arm. Torque screw.
(13). Environmentally seal bolt heads and (21). Fully examine inner side of fuel cell for
washers, use sealing compound (C207) unwanted material before you install
(Ref. CSP-SPM). fuel cell cover.
Grease (C109)
NOTE: If new fuel cell is new, do the fuel cell
baffle lacing cord deflection inspection. This
inspection is not necessary if same fuel cell
is installed and baffle lacing cords have not
moved.
(14). Lubricate new o-rings (7, Figure 407)
with grease (C109) and install on fuel
cell filler neck and gravity filler neck. (22). Install fuel cell access cover.
Page 403
(23). Install panels AL155, AR155, A160, (26). Do the fuel quantity indicating system
AL165, AR165, A170, A217, AL230, functional test.
(27). If necessary, install carpet (Ref. Section
(24). Install panel B178 (Ref. Section
25-20-00).
06-00-00).
(25). Do the fuel cell leak check/pressure (28). If necessary, install cabin seats (Ref.
test. Section 25-20-00).
Page 404
16
15
16
14
18
1 17
3 11 11
5 10
7
17
NOTE
13
6
12
12
NOTE:
FUEL CROSSFEED SYSTEM REMOVED ON 900 CONFIG HELICOPTERS CONVERTED TO PW207E ENGINES. 9G28-022-1C
Figure 401. Fuel System (900 CONFIG) (Sheet 1 of 3)
Page 405
16
15
16
14
18
17
1
2
3 11
11
12
(2 PL)
10
4
5
6
17
7
9G28-022-2A
Figure 401. Fuel System (902 CONFIG) (Sheet 2 of 3)
Page 406
Original 28-00-00
23
25
24
4 REF RIGHT KEEL BEAM

REF FUEL CELL STANDOFF
PART OF FUEL CELL 26
21
27 20
19
REF 22
FUSELAGE
29
28
29
28
30
30
G28-022-3
1. FUEL CELL 16. ENGINE DECK FRANGIBLE VALVE

2. FUEL CELL ACCESS COVER 17. DUAL VENT ROLLOVER VALVE
3. FUEL FILLER NECK GRAVITY FILL PORT 18. FUEL VENT SYSTEM
4. FUEL FILL PORT CHECK VALVE 19. SCREW
5. FUEL SUMP DRAIN VALVE CONTROL ASSEMBLY 20. WASHER
6. CENTRIFUGAL FUEL BOOSTER PUMP 21. CLAMP
7. FUEL SUPPLY CHECK VALVE 22. FUEL SUPPLY HOSE
8. FORWARD FUEL GAUGING PROBE 23. BOLT
9. AFT FUEL GAUGING PROBE 24. WASHER
10. FUEL CELL FRANGIBLE VALVE 25. ORING
11. SINGLE VENT ROLLOVER VALVE 26. BOLT
12. FUEL PRESS. SWITCHINTERCONNECT TEE FITTING 27. WASHER
13. CROSSFEED SHUTOFF VALVE 28. BOLT
14. LH FUEL SHUTOFF VALVE 29. WASHER
15. RH FUEL SHUTOFF VALVE 30. FUEL SUMP DRAIN VALVES
Figure 401. Fuel System (Sheet 3 of 3)
Page 407
28-00-00 Original
2. Fuel Cell Access Cover (1). Prepare access cover surface for
electrical bonding (Ref. CSP-SPM).
A. Fuel Cell Access Cover Removal
Grease (C109)
(Ref. Figure 402)
(2). Lubricate O-rings (4) with grease

(C109) and install on fuel cell cover (3).
(1). Defuel helicopter (Ref. Section (3). Install fuel cell access cover (3) on fuel
12-00-00). cell.
(2). Remove cabin seats, if applicable (Ref. (4). Attach electrical bonding jumper (5) in
Section 25-20-00). original location on fuel cell cover with
bolt (1) and washer (2).
Section 25-20-00. (5). Install remaining bolts (1) and washers
(2). Torque bolts.
(4). Remove cabin floor panels AL165,
AR165, A170 (Ref. Section 53-20-00). Sealing Compound (C207)
CAUTION
NOTE: Record electrical bonding jumper loca

tion on each fuel cell cover. Reinstall in the (6). Apply sealing compound (C207) over
same location as removed. bonding jumper area attachment bolts
(Ref. CSP-SPM).
(5). Remove bolt (1) and washer (2),
disconnecting electrical bonding jumper (7). Install cabin floor panels AL165,
(5) from fuel cell cover (3). Clean all AR165, A170 (Ref. Section 53-20-00).
sealant compound from bonded area NOTE:
(Ref. CSP-SPM).
Use fuel cell rod (T801) through hole in
(6). Remove remaining bolts (1) and floor panel to lift top of fuel cell for instal
washers (2) attaching fuel cell covers to lation of screws to support fuel cell to floor
fuel cell. Remove cover and discard panel. Install vapor seal plug in floor pan
O-rings (4). el hole (Ref. Section 53-20-00).
As an alternate method use high grade
B. Fuel Cell Access Cover Installation
steel all thread rods with large surface
(Ref. Figure 402) flat washers and nuts. Insert threaded
rods through floor panel and threaded
hole in fuel access panel. Place large sur
Consumable Materials face flat washers over floor panel and
(Ref. CSPSPM) threaded rods. With nuts installed on
Item Nomenclature threaded rods, turn the nuts down evenly
C109 Grease until fuel cell is located in correct position
C207 Sealing Compound, Fuel Resistant to cabin floor panel.
(8). Perform fuel cell leak check/pressure
test (Ref. Section 28-00-00).
Special Tools
(Ref. CSPSPM) (9). Install carpet, if applicable (Ref. Section
T801 Fuel Cell Rod (10). Install cabin seats, if applicable (Ref.
Section 25-20-00).
Page 408
Original 28-00-00
(11). Fuel helicopter (Ref. Section 12-00-00). System Contamination

CAUTION
1 (5). Remove forward fuel cell access cover.

2 (6). Remove sump access panel B178 (Ref.
5
Section 06-00-00).
6
(7). Disconnect wire harness (10).
3
(a). Remove screw (16) and disconnect:
A111 (Q12D16) wire from left
booster pump positive (+) terminal.
4 A112 (Q13C16) wire from right
booster pump positive (+) terminal.
(b). Remove hex head screw (17), push up
on shut-off lever arm so screw will
turn freely: Disconnect A111
(Q35A16N) and (Q35B16) wire from
left booster pump negative (-)
terminal. A112 (Q36A16N) and
(Q36B16) wire from right booster
9G28-006 pump negative (-) terminal.
1. BOLT (8). Remove and discard lockwire. Remove
2. WASHER bleeder/drain plug (12) and packing
3. COVER
(11). Discard packing. Drain fuel into
4. ORING
5. ELECTRICAL BONDING JUMPER an applicable container.
6. SCREW (INSTALLED THROUGH CABIN FLOOR)
(9). Disconnect fuel hose (1).
Figure 402. Fuel Cell Access Cover
(10). 900 CONFIG - Remove fittings from
3. Centrifugal Fuel Booster Pump booster pump outlet as follows:
A. Centrifugal Fuel Booster Pump Removal (a). PW206A Remove fuel supply check
valve (3) and packing (4). Discard
(Ref. Figure 403) packing.
NOTE: This task is typical for left and right (b). PW206E/PW207E Remove union
centrifugal fuel booster pump removal. (22) and packing (4). Discard pack
ing.
(c). Remove reducer bushing (5) and
packing (6). Discard packing.
(11). 902 CONFIG - Remove fittings from
booster pump outlet as follows:
(1). Defuel helicopter (Ref. Section
12-00-00). (a). Disconnect tube (28).
(2). If necessary, remove cabin seats (Ref. (b). Remove nut (26), adapter (27), tee
Section 25-20-00). (24), reducer (25), and packing (4).
Discard packing.
(3). If necessary, remove carpet (Ref.
Section 25-20-00. (12). Remove and discard lockwire. Remove
bleeder/drain plug (14) and packing
(4). Remove cabin floor panels AL165, (13). Discard packing. Drain fuel into
AR165, A170 (Ref. Section 53-20-00). an applicable container.
Page 409
(13). Remove bolt (7 or 21) and washer (8). Finish Enamel, Black (C303)
NOTE: Pump must be installed in same posi

tion as removed. Note direction stripe points
during removal.
(2). Paint alignment stripe on fuel booster
pump at same location as removed
(14). S/N 0008-0032 -Remove bolts (15) and pump, use black finish enamel (C303).
washers (8).
Grease (C109)
(15). S/N 0033-SUBS - Remove bolts (15
and 20) and washers (8).
Do not touch or damage red um

CAUTION brella shaped check valve on top
(3). Lubricate packing with grease (C109)
and install on fuel booster pump.
of fuel booster pump. Fuel booster pump
failure can occur. Do not touch or damage red um
CAUTION brella shaped check valve on top
of fuel booster pump. Fuel booster pump
(16). S/N 0008-0032 -Remove fuel booster
failure can occur.
pump (2) and packing (9). Discard
packing. Drain fuel into an applicable (4). S/N 0008-0032 -Carefully install fuel
container. booster pump, align stripe. Install bolts
and washers, install bolt (7) adjacent to
(17). S/N 0033-SUBS - Remove fuel booster bleeder/drain plug. Torque bolts.
pump (2), support ring (18), laminated
(5). S/N 0033-SUBS - Install fuel booster
shim (19), and packing (9). Discard
pump as follows:
packing. Drain fuel into an applicable
container. (a). Make sure laminated shim has a
thickness of 0.056-0.057 in.
B. Centrifugal Fuel Booster Pump (1.422-1.448 mm).
Installation (b). Install laminated shim, fuel booster
pump, support ring, bolts and
(Ref. Figure 403) washers, install bolt (21) adjacent to
bleeder/drain plug. Torque bolts.
NOTE: This task is typical for left and right (6). Lubricate packing with grease (C109)
centrifugal fuel booster pump installation. and install on bleeder/drain plug (12).
(7). Install bleeder/drain plug. Torque plug
Consumable Materials 280-305 in-lb (31.6-34.5 Nwm) and
(Ref. CSPSPM) safety to bolt, use lockwire (C702).
Item Nomenclature
(8). Lubricate packing with grease (C109)
C109 Grease and install on bleeder/drain plug (14).
C702 Lockwire (9). Install bleeder/drain plug. Torque plug
C303 Finish Enamel, Black 95-105 in-lb (10.7-11.9 Nwm) and
safety to bolt, use lockwire (C702).
Do not tighten screws too much.
(1). Prepare fuel booster pump attach CAUTION
surface for electrical bond (Ref. CSP-
SPM). (10). Connect wire harness as follows:
Page 410
(a). Connect A111 (Q12D16) wire to left (d). Install reducer and tube nut. Torque
booster pump positive (+) terminal. tube nut 230-260 in-lb (26-29.4
A112 (Q13C16) wire to right booster Nwm).
pump positive (+) terminal and
install (short) straight slot screw. (e). Connect tube. Torque tube nut 50-65
in-lb (5.65-7.34 Nwm).
(b). Connect A111 (Q35A16N) and
(Q35B16) wire to left booster pump (13). Connect fuel hose. Torque fuel supply
negative (-) terminal. A112 hose nut 230-260 in-lb (26-29.4 Nwm).
(Q36A16N) and (Q36B16) wire to (14). Install forward fuel cell access cover
right booster pump negative (-) (Ref. Section 28-00-00).
terminal. Install hex head screw,
push up on shut-off lever arm so (15). Install cabin floor panels AL165,
screw will turn freely. Torque screw. AR165, A170 (Ref. Section 53-20-00).
(11). 900 CONFIG - Install fittings in (16). Do the fuel cell leak check/pressure
booster pump as follows: test.
(a). Lubricate packing with grease (C109) (17). Install sump access panel B178 (Ref.
and install on reducer bushing. Section 06-00-00).
(b). Install reducer bushing. Torque (18). Fuel helicopter (Ref. Section 12-00-00).
reducer bushing 380-405 in-lb
(42.9-45.8 Nwm). (19). Do the fuel booster pump operational
test.
(c). (PW206A) Lubricate packing with
grease (C109) and install on fuel (20). If necessary, install carpet (Ref. Section
supply system check valve. 25-20-00).
(d). (PW206A) Install check valve. (21). If necessary, install cabin seats (Ref.
Torque check valve 280-305 in-lb Section 25-20-00).
(31.6-34.5 Nwm).
C. Centrifugal Fuel Booster Pump Umbrella
(e). (PW206E/PW207E) Lubricate Shaped Check Valve Removal
packing with grease (C109) and
install on union. NOTE: You can only change the umbrella
shaped check valve in the fuel booster pump
(f). (PW206E/PW207E) Install union. cartridge housing.
Torque union 280-305 in-lb
(31.6-34.5 Nwm). (1). Remove fuel booster pump.
(12). 902 CONFIG - Install fittings in (2). Remove fuel booster pump cartridge.
booster pump as follows: (3). Remove check valve (23).
(a). Lubricate packing with grease (C109) D. Centrifugal Fuel Booster Pump Umbrella
and install on reducer. Shaped Check Valve Installation
(b). Install reducer. Torque reducer (1). Install check valve.
380-405 in-lb (42.9-45.8 Nwm).
(2). Install fuel booster pump cartridge.
(c). Install tee. Torque tee 230-260 in-lb
(26-29.4 Nwm). (3). Install fuel booster pump.
Page 411
26 24
27
28
1
22 25
3
902 CONFIG
900 CONFIG WITH
206E OR 207E ENGINES 5
4
23
2
8
8
6 13 10
7
10
9 10 11
12
16
15
14 17 BOTTOM VIEW
SERIAL NUMBER
33 AND SUBSEQUENT 19
18
8 (3 PL) 8
20 (3 PL) 8 (4 PL) 21
15 (4 PL)
9G28-012C
1. FUEL HOSE 15. BOLT

2. FUEL BOOSTER PUMP 16. SCREW
3. FUEL SUPPLY CHECK VALVE (900 CONFIG PW206A) 17. HEX HEAD SCREW
4. PACKING (900 CONFIG) 18. SUPPORT RING
5. REDUCER BUSHING (900 CONFIG) 19. LAMINATED SHIM
6. PACKING (900 CONFIG) 20. BOLT
7. BOLT 21. BOLT
8. WASHER 22. UNION (900 CONFIG WITH PW206E/PW207E)
9. PACKING 23. CHECK VALVE
10. WIRE HARNESS (A111 LEFT, A112 RIGHT) 24. TEE
11. PACKING 25. REDUCER
12. BLEEDER/DRAIN PLUG 26. NUT
13. PACKING 27. ADAPTER
14. BLEEDER/DRAIN PLUG 28. TUBE
Figure 403. Centrifugal Fuel Booster Pump
Page 412
4. Centrifugal Fuel Booster Pump Cartridge Aviation Turbine Fuel

Replacement
A. Fuel Booster Pump Cartridge Removal
(3). Rotate fuel shut-off lever arm 180 out

(Ref. Figure 404) of the way of the pump cartridge. This
lever shuts off fuel to the pumping
NOTE: This task is typical for LH and RH Cen cavity. Upon removal of the pump
trifugal Fuel Booster Pump Cartridge re cartridge, approximately 1 pint (0.473
moval. liters) of fuel will be lost. Drain fuel into
suitable container.
(4). Remove and discard lockwire securing
(Ref. CSPSPM)
bleeder/drain plug (7, Ref. Figure 404)
Item Nomenclature
from bottom of pump cartridge (2).
Remove and discard O-ring (6).
C802 Cloth, NonLint
(5). Remove Spirolox retaining ring (5) from
bottom of fuel pump.
Special Tools (6). Install cartridge pulling tool (T802) (8)

(Ref. CSPSPM) in pump cartridge drain boss.
Item Nomenclature
(7). Slide the impact hammer of pulling tool
T802 Cartridge Pulling Tool downward, impacting the bolt head.
Pull pump cartridge (2) straight
downward and remove from fuel pump
(1). Remove sump access panel assembly housing (9).
B178 (Ref. Section 06-00-00).
(8). Remove and discard O-rings (3, 4).
(2). Detach wire harness (10, Ref. System Contamination

Figure 403). CAUTION
(9). Clean pump cartridge cavity and

(a). Remove straight slot (short) screw Spirolox retaining ring with non-lint
(16) and disconnect: cloth (C802).
A111 (Q12D16) wire from left
booster pump positive (+) terminal. B. Fuel Booster Pump Cartridge Installation
A112 (Q13C16) wire from right
booster pump positive (+) terminal. (Ref. Figure 404)
(b). Remove (long) Allen drive shoulder NOTE: This task is typical for LH and RH Cen
screw (17). While applying upward trifugal Fuel Booster Pump Cartridge
pressure to the shut-off lever arm to installation.
prevent binding of the Allen drive
shoulder screw, remove: Consumable Materials
A111 (Q35A16N) and (Q35B16) wire (Ref. CSPSPM)
from left booster pump negative (-) Item Nomenclature
terminal.
A112 (Q36A16N) and (Q36B16) wire C109 Grease
from right booster pump negative (-) C702 Lockwire
terminal.
Page 413
28-00-00 Original
Grease (C109) (8). Rotate fuel shut-off lever arm 180 to

align with the pump cartridge negative
terminal.
(9). Visually check for fuel leaks.

(1). Lubricate O-rings (3 and 4) with grease
(C109) and install on fuel booster pump Do not over torque terminal
CAUTION screws.
cartridge (2).
Do not use cartridge pulling tool (10). Attach wire harness (10, Ref.
CAUTION (T802) to insert pump cartridge. Figure 403).
(2). Position pump cartridge (2) so that
(a). Attach (short) straight slot screw (16)
arrow aligns with arrow on fuel pump
and:
housing (9).
A111 (Q12D16) wire to left booster
(3). Insert pump cartridge into fuel booster pump positive (+) terminal.
pump housing. Use hands only, to push A112 (Q13C16) wire to right booster
pump cartridge into place. pump positive (+) terminal.
(4). Make sure that pump cartridge is (b). While pressing upward on the stem
properly seated and Spirolox retaining of lever arm, secure negative wire
ring groove is not obstructed. and case ground wire by inserting
(long) Allen drive shoulder screw (17)
(5). Install Spirolox retaining ring (5) in
into position and tighten. Be sure to
bottom of fuel booster pump to retain
have wires between shoulder on
cartridge.
screw and lever arm. Attach:
Grease (C109) A111 (Q35A16N) and (Q35B16) wire
to left booster pump negative (-)
terminal.
A112 (Q36A16N) and (Q36B16) wire
to right booster pump negative (-)
(6). Lubricate O-ring (6) with grease terminal.
(C109) and install on bleeder/drain plug
(7). Install bleeder/drain plug in pump (11). Perform fuel booster pump operational
cartridge. Torque bleeder/drain plug (7). test (Ref. Section 28-00-00).
(7). Secure bleeder/drain plug (7) with (12). Install sump access panel assembly
lockwire (C702). B178 (Ref. Section 06-00-00).
Page 414
Original 28-00-00
1
BOTTOM VIEW
2
3 9
5 4
8
7 9G28-013A
1. FUEL BOOSTER PUMP 6. ORING

2. PUMP CARTRIDGE 7. BLEEDER/DRAIN PLUG
3. ORING 8. CARTRIDGE PULLING TOOL (T802)
4. ORINGS 9. FUEL PUMP HOUSING
5. SPIROLOX RETAINING RING
Figure 404. Centrifugal Fuel Booster Pump (Cartridge Only) Replacement
5. Forward Fuel Gauging Probe System Contamination

CAUTION
A. Forward Fuel Gauging Probe Removal
(5). Remove LH forward fuel cell access
(Ref. Figure 405) cover (Ref. Section 28-00-00).
(6). Remove sump access panel assembly

B178 (Ref. Section 06-00-00).
(7). 900 CONFIG - Detach forward fuel

gauging probe connector P1 A104 (6)
from mating connector J222 (8).
(8). 902 CONFIG - Detach left fuel
12-00-00).
from mating connector J222 (8).
(2). Remove cabin seats, if applicable (Ref.
Section 25-20-00). (9). Remove bolts (4) and washers (3)
attaching forward fuel gauging probe
(3). Remove carpet, if applicable (Ref. (1) to fuel cell.
Section 25-20-00).
(10). Carefully remove forward fuel gauging
(4). Remove cabin floor panels; AL165, probe (1) from fuel cell and discard
AR165, A170 (Ref. Section 53-20-00). O-ring (5).
Page 415
28-00-00 Original
B. Forward Fuel Gauging Probe Installation (12). Install cabin seats, if applicable (Ref.
Section 25-20-00).
(Ref. Figure 405)
6. Aft Fuel Gauging Probe
(Ref. CSPSPM)
Item Nomenclature
A. Aft Fuel Gauging Probe Removal
C109 Grease
(Ref. Figure 405)
(1). Prepare probe surface for electrical Aviation Turbine Fuel

bonding (Ref. CSP-SPM).
Grease (C109)

12-00-00).
(2). Lubricate O-ring (5) with grease
(C109) and install in forward fuel (2). Remove cabin seats, if applicable (Ref.
gauging probe mating fuel cell fitting Section 25-20-00).
groove.
(3). Carefully place forward fuel gauging (3). Remove carpet, if applicable (Ref.
probe in position in fuel cell. Install Section 25-20-00).
bolts (4) and washers (3). Torque bolts.
(4). Remove cabin floor panels AL165,
(4). 900 CONFIG - Attach forward fuel AR165, A170 (Ref. Section 53-20-00).
gauging probe connector P1 A104 (6) to
mating connector J222 (8).
CAUTION
(5). 902 CONFIG - Attach left fuel gauging
probe connector P1 A107 (6) to mating
connector J222 (8) (5). Remove RH forward fuel cell access
cover (Ref. Section 28-00-00).
(6). Install LH forward fuel cell access cover
(7). Install sump access panel assembly B178 (Ref. Section 06-00-00).
B178 (Ref. Section 06-00-00).
(7). 900 CONFIG - Detach aft fuel gauging
(8). Install cabin floor panels AL165, probe connector P1 A107 (7) from
AR165, A170 (Ref. Section 53-20-00). mating connector J223 (9).
test (Ref. Section 28-00-00). (8). 902 CONFIG - Detach right fuel
NOTE: Fuel helicopter (Ref. Section 12-00-00) from mating connector J223 (9).
in conjunction with fuel quantity indicating
system functional test.. (9). Remove bolts (4) and washers (3)
attaching aft fuel gauging probe (2) to
(10). Perform fuel quantity indicating system
fuel cell.
functional test (Ref. Section 28-00-00).
(11). Install carpet, if applicable (Ref. Section (10). Carefully remove aft fuel gauging probe
25-20-00). (2) from fuel cell and discard O-ring (5).
Page 416
Original 28-00-00
B. Aft Fuel Gauging Probe Installation

(Ref. Figure 405)
(Ref. CSPSPM) 2
Item Nomenclature
10
C109 Grease 1
11
(1). Prepare probe surface for electrical
Grease (C109)

(C109) and install in aft fuel gauging
probe mating fuel cell fitting groove.
5 3
(3). Carefully place aft fuel gauging probe 4
in position in fuel cell. Install bolts (4)
and washers (3). Torque bolts. 3
(4). 900 CONFIG - Attach aft fuel gauging 4

probe connector P1 A107 (7) to mating 6
connector J223 (9). 8
(5). 902 CONFIG - Attach right fuel

gauging probe connector P1 A104 (7) to
mating connector J223 (9).
7
(6). Install RH forward fuel cell access cover 9
(7). Install sump access panel assembly
B178 (Ref. Section 06-00-00). 9G28-014A

AR165, A170 (Ref. Section 53-20-00). 1. FUEL GAUGING PROBE, FORWARD (900 CONFIG),
LEFT 902 CONFIG
(9). Perform fuel cell leak check/pressure 2. FUEL GAUGING PROBE, AFT (900 CONFIG),
RIGHT (902 CONFIG)
test (Ref. Section 28-00-00). 3. WASHER
4. BOLT
NOTE: Fuel helicopter (Ref. Section 12-00-00) 5. ORING
in conjunction with fuel quantity indicating 6. CONNECTOR (P1 A104) (900 CONFIG),
system functional test.. (P1 A107) (902 CONFIG)
7. CONNECTOR (P1 A107) (900 CONFIG),
(10). Perform fuel quantity indicating system (P1 A104) (902 CONFIG)
functional test (Ref. Section 28-00-00). 8. CONNECTOR (J222)
9. CONNECTOR (J223)
(11). Install carpet, if applicable (Ref. Section 10. FUEL LOW LEVEL SENSOR (900 CONFIG),
25-20-00). RIGHT LOW LEVEL SENSOR (902 CONFIG)
11. LEFT LOW LEVEL SENSOR (902 CONFIG)
Section 25-20-00). Figure 405. Fuel Gauging Probes
Page 417
28-00-00 Original
19 (2 PL) 14 (4 PL)
20 (2 PL) 15 (4 PL)
21 (2 PL) 22 (2 PL) 16 (4 PL)
18 (2 PL)
17 (4 PL)
4 (2 PL)
2
23 (2 PL)
25 (2 PL)
26 (2 PL)
27 (X2 2 PL)
28 (2 PL)
1 24 (2 PL)
11 (2 PL)
12 (X2 2 PL)
13 (X2 2 PL)
3 (2 PL)
5 (2 PL)
6 (2 PL)
7 (2 PL)
8 (2 PL)
9 (2 PL)
10 (2 PL) 9G28-050
1. FORWARD (LEFT SIDE) FUEL GAUGING PROBE 15. BOLT
2. AFT (RIGHT SIDE) FUEL GAUGING PROBE 16. SPACER
3. FUEL BOOSTER PUMP 17. WASHER
4. HOSE ASSEMBLY, BOOSTER TO FUEL CELL OUTLET 18. CHECK VALVE
5. TEE 19. PACKING
6. PACKING 20. BUSHING
7. REDUCER 21. PACKING
8. PACKING 22. JET PUMP
9. REDUCER 23. TUBE ASSEMBLY, BOOSTER TO JET PUMP
10. TUBE NUT 24. TUBE ASSEMBLY, JET PUMP TO OUTLET
11. BRACKET ASSEMBLY 25. CLAMP
12. BOLT 26. BOLT
14. CLAMP 28. NUT
Figure 406. Fuel Pump, Gauging, and Transfer Systems (902 CONFIG)
Page 418
Original 28-00-00
7. Gravity Fill Port Filler Neck (1). Prepare filler neck surface for electrical
A. Gravity Fill Port Filler Neck Removal
Sealant, Conductive (C229)
(Ref. Figure 407)
(2). Apply sealant (C229) between range

extender if installed, fuel filler neck
flange and fuselage faying surfaces
(1). Defuel helicopter (Ref. Section (Ref. CSP-SPM).
12-00-00).
(3). Install bolts (3) and washers (4)
(2). Remove cabin seats, if applicable (Ref. through range extender if installed,
Section 25-20-00). filler neck flange (5) and aircraft outer
skin. Torque bolts.
Section 25-20-00). Grease (C109)
(4). Remove cabin floor panel AR165 (Ref.

Section 53-20-00).
(5). Open fuel filler cap (1) and disconnect
filler cap lanyard (2) from fill port check (4). Lubricate O-rings (7) with grease
valve lanyard. (C109) and install on filler neck fitting
(6) and fuel cell fitting (9).
CAUTION NOTE: Retainer (16) is installed as part of the
lightening protection to ensure no contact
(6). Remove bolts (3) and washers (4) from between the filler neck (6) and the fuel cell
range extender if installed, and filler fitting (9).
neck flange (5). (5). Position retainer (16) and install
(7). Remove flexible coupling (8) connecting flexible coupling (8).
filler neck fitting (6) to fuel cell fitting (6). Connect fuel filler cap lanyard (2) to
(9), retain retainer (16) for reinstalla check valve lanyard and install fuel
tion. Remove filler neck and discard filler cap (1).
O-rings (7).
(7). Install cabin floor panel AR165 (Ref.
B. Gravity Fill Port Filler Neck Installation Section 53-20-00).
(Ref. Figure 407) (8). Perform fuel cell leak check/pressure
Consumable Materials (9). Install carpet, if applicable (Ref. Section
(Ref. CSPSPM) 25-20-00).
Item Nomenclature
C109 Grease (10). Install cabin seats, if applicable (Ref.
Section 25-20-00).
C229 Sealant, Conductive
(11). Fuel helicopter (Ref. Section 12-00-00).
Page 419
28-00-00 Revision 1
8. Fuel Fill Port Check Valve Assembly (1). Prepare fill port check valve assembly
and fuel cell fitting faying surfaces for
A. Fuel Fill Port Check Valve Assembly electrical bonding (Ref. CSP-SPM).
Removal
Grease (C109)
(Ref. Figure 407)

(C109) and install on check valve
(1). Defuel helicopter (Ref. Section assembly (14).
12-00-00). (3). Align check valve to correct orientation
(2). Remove cabin seats, if applicable (Ref. marked UP on valve. Install check
Section 25-20-00). valve assembly in fuel cell with nuts
(13) and washers (12). Torque nuts.
Section 25-20-00). (4). Connect check valve lanyard (2) to fuel
filler cap lanyard. Install fuel filler cap
(4). Remove cabin floor panels AL155, (1).
AR155, A160, AL165, AR165, A170
(Ref. Section 53-20-00). (5). 902 CONFIG - Connect cable to center
baffle check valve.
CAUTION (a). Connect cable to center baffle check
valve.
(5). Remove right forward fuel cell access
cover (Ref. Section 28-00-00). (b). Adjust cable length to allow 0.50
inch (12.70 mm) slack when center
(6). Open fuel filler cap (1) and disconnect baffle check valve is in closed posi
filler cap lanyard (2) from check valve tion. Add or remove split rings, as
lanyard. necessary.
(7). 902 CONFIG - Disconnect cable from (c). Center baffle check valve must open
center baffle check valve (15). at least 45 degrees when fill port
(8). Remove nuts (13) and washers (12) check valve is fully open.
attaching check valve assembly (14) to (6). Install right forward fuel cell access
fuel cell. cover (Ref. Section 28-00-00).
(9). Remove check valve from fuel cell and (7). Install cabin floor panels AL155,
discard O-ring (11). AR155, A160, AL165, AR165, A170
B. Fuel Fill Port Check Valve Assembly (Ref. Section 53-20-00).
Installation (8). Perform fuel cell leak check/pressure
(Ref. Figure 407) test (Ref. Section 28-00-00).
(9). Install carpet, if applicable (Ref. Section
Consumable Materials 25-20-00).
(Ref. CSPSPM)
Item Nomenclature (10). Install cabin seats, if applicable (Ref.
Section 25-20-00).
C109 Grease
Page 420
Revision 1 28-00-00
4 10
16 12 14
13
11 902 CONFIG
2
6
7
8 9
15
9G28-037 LOOKING INBD RIGHT SIDE
1. FUEL FILLER CAP 9. FUEL CELL FITTING
2. LANYARD 10. ORING
3. BOLT 11. ORING
5. FILLER NECK FLANGE 13. NUT
6. GRAVITY FILLER NECK 14. CHECK VALVE ASSEMBLY
7. ORING 15. CENTER BAFFLE CHECK VALVE (902 CONFIG)
8. FLEXIBLE COUPLING 16. RETAINER, PACKING BACKUP
Figure 407. Gravity Fill Port Filler Neck and Check Valve
Page 421
28-00-00 Revision 1
9. Range Extender (1). Prepare range extender and fuel filler

neck surfaces for electrical bonding
A. Range Extender Removal (Ref. CSP-SPM).
(Ref. Figure 408)
Aviation Turbine Fuel Sealant, Conductive (C229)

12-00-00). (2). Apply sealant (C229) between range
(2). Open fuel filler cap (1) and disconnect extender flange (6), fuel filler neck
filler cap lanyard (2) from fill port check flange (5) and fuselage faying surfaces
valve lanyard. (Ref. CSP-SPM).
CAUTION (3). Install bolts (3) and washers (4)
(3). Remove bolts (3) and washers (4) from through range extender flange (6), fuel
range extender flange (6) and remove filler neck flange (5) and aircraft outer
range extender. skin. Torque bolts.
B. Range Extender Installation
(4). Connect filler cap lanyard (2) to check
(Ref. Figure 408) valve lanyard and install filler cap (1).
(Ref. CSPSPM)
Item Nomenclature
1 5
2
3
4
9G28-047
1. FILLER CAP 4. WASHER

2. LANYARD 5. FILLER NECK FLANGE
3. BOLT 6. RANGE EXTENDER
Figure 408. Range Extender
Page 422
Original 28-00-00
10. Single Port Fuel Vent Float/Rollover Valve B. Single Port Fuel Vent Float/Rollover
Valve Installation
A. Single Port Fuel Vent Float/Rollover
Valve Removal (Ref. Figure 409)
(Ref. Figure 409) NOTE: This task is typical for LH aft and RH
forward Single Port Fuel Vent Float/Rol
NOTE: This task is typical for LH aft and RH lover Valve installation, except where noted.
forward Single Port Fuel Vent Float/Rol
lover Valve removal, except where noted.
Aviation Turbine Fuel (Ref. CSPSPM)
Item Nomenclature
C109 Grease
C702 Lockwire
12-00-00).
(1). Prepare single port float/rollover valve
(2). Remove cabin seats, if applicable (Ref. surface for electrical bonding (Ref.
Section 25-20-00). CSP-SPM).
Grease (C109)
Section 25-20-00).
(4). Remove cabin floor panels AR155 and

AL230 (Ref. Section 53-20-00).

fuel vent hose (7) to single port fuel
(C109) and install on float/rollover
vent float/rollover valve (8). Remove valve (8).
vent hose from float/rollover valve.
(6). Disconnect electrical bonding jumpers. (3). Position float/rollover valve on fuel cell.
(a). If removing right forward single port (4). Connect electrical bonding jumpers.
float/rollover valve, remove bolt (1)
and washer (2) and disconnect (a). If installing right forward single port
electrical bonding jumpers (3) from float/rollover valve, connect electrical
float/rollover valve. bonding jumpers (3) with bolt (1) and
washer (2) and install at inboard
(b). If removing left aft single port position.
float/rollover valve, remove and
discard lockwire from bolt (1) and (b). If installing left aft single port
plug (4). Remove bolt (1) and washer float/rollover valve, connect electrical
(2) and disconnect electrical bonding bonding jumpers (3) with bolt (1) and
jumpers (3) from float/ rollover valve. washer (2) and install at inboard
position. Torque bolt and safety to
System Contamination plug (4) with lockwire (C702).
CAUTION
(7). Remove remaining bolts (5) and washer (5). Install remaining bolts (5) and washer
(6) attaching float/rollover valve (8) to (6) attaching float/rollover valve to fuel
fuel cell. cell. Torque bolts.
(8). Remove float/rollover valve and discard (6). Perform electrical bond testing (Ref.
O-ring (9). CSP-SPM).
Page 423
28-00-00 Original
Sealing Compound (C206) (9). Install cabin floor panels AR155 and
AL230 (Ref. Section 53-20-00).(Ref.
Section 53-20-00).
(7). Apply sealing compound (C206) to bolts (11). Install carpet, if applicable (Ref. Section
(Ref. CSP-SPM). 25-20-00).
(8). Install fuel vent hose (7) on float/rol Section 25-20-00).
lover valve (8). Secure vent hose with
lockwire (C702). (13). Fuel helicopter (Ref. Section 12-00-00).
1 7 5
4
1
5 8
6 2
2
3
6
9 8
9
RIGHT-HAND FWD LEFT-HAND AFT 9G28-019

1. BOLT 6. WASHER
2. WASHER 7. VENT HOSE
3. ELECTRICAL BONDING JUMPER 8. SINGLE PORT FUEL VENT FLOAT/ROLLOVER VALVE
4. PLUG 9. ORING
5. BOLT
Figure 409. Single Port Fuel Vent Float/Rollover Valves
Page 424
Original 28-00-00
11. Dual Port Fuel Vent Float/Rollover Valve System Contamination

CAUTION
A. Dual Port Fuel Vent Float/Rollover Valve
Removal (8). Remove remaining bolts (6) and
washers (7) attaching float/rollover
(Ref. Figure 410) valve to fuel cell.
Aviation Turbine Fuel (9). Remove float/rollover valve and discard

O-ring (9).
B. Dual Port Fuel Vent Float/Rollover Valve
Installation
(Ref. Figure 410)
12-00-00).
(2). Removal cabin seats, if applicable (Ref. (Ref. CSPSPM)
Section 25-20-00). Item Nomenclature
C109 Grease
(3). Remove carpet, if applicable (Ref. C206 Sealing Compound
Section 25-20-00). C242 Adhesion Promoter
(4). Remove cabin floor panels AL155 and C432 Cleaner
AR230 (Ref. Section 53-20-00). C702 Lockwire
C817 Pad, Scouring, Cellulose/Nylon
(5). Disconnect aft right or early type
forward left float/rollover valve.
(1). Prepare dual float/rollover valve
(a). Remove and discard lockwire secur surface for electrical bonding (Ref.
ing fuel vent hoses (5) to float/ CSP-SPM).
rollover valve (4). Grease (C109)
(b). Disconnect vent hoses (5) from
float/rollover valve vent tube (4).
(6). Disconnect later type forward left

float/rollover valve. (2). Lubricate O-ring (9) with grease
(C109) and install on float/rollover
NOTE: Forward side of forward left float/rol valve (8).
lover valve, has plastic vent duct attached
(3). Position float/rollover valve (8) on fuel
with sealing compound.
cell.
(a). Remove lockwire and disconnect vent (4). Connect electrical bonding jumpers (3)
hose (5) from float/rollover valve vent with bolt (1) and washer (2) and install
tube. at inboard position.
(b). Remove sealing compound from (5). Install remaining bolts (6) and washers
transition duct (11) and grommet (7) attaching dual float/rollover valve to
(12). fuel cell. Torque bolts.
(c). Disconnect transition duct from (6). Perform electrical bond testing (Ref.
float/rollover valve and elbow duct CSP-SPM).
(10) and remove from bulkhead. (7). Connect aft right or early type forward
left float/rollover valve.
(7). Remove bolt (1) and washer (2) and
disconnect electrical bonding jumpers (a). Connect fuel vent hoses (5) to aft
(3) from float/rollover valve (8). float/rollover valve vent tube (4).
Page 425
28-00-00 Original
(b). Secure fuel vent hoses with lockwire NOTE: If necessary, float/rollover valve bolts
(C702). can be loosened to allow transition duct
installation. Retorque bolts after installa
(8). Connect later type forward left float/ tion.
rollover valve.
Sealing Compound (C206) (e). Apply sealing compound (C206) to
faying surfaces. Install transition
duct and grommet through bulkhead,
and connect to float/rollover valve
and elbow duct. Allow sealing
compound to cure before fueling
Adhesion Promoter (C242) aircraft.
(9). Apply sealing compound (C206) to bolts

(Ref. CSP-SPM).
(a). Install fuel vent hose (5) on float/ (10). Install cabin floor panels AL155 and
rollover valve. AR230 (Ref. Section 53-20-00).
(b). Clean residual sealing compound (11). Perform fuel cell leak check/pressure
from transition duct (11), elbow duct test (Ref. Section 28-00-00).
(10), float/rollover valve (8), and
grommet (12) faying surfaces as (12). Install carpet, if applicable (Ref. Section
required. Use cleaner (C432). 25-20-00).
(c). Lightly abrade faying surfaces. Use
scouring pad (C817). (13). Install cabin seats, if applicable (Ref.
Section 25-20-00).
(d). Apply adhesion promoter (C242) to
faying surfaces and allow to dry. (14). Fuel helicopter (Ref. Section 12-00-00).
Page 426
Original 28-00-00
1
2
6 3
7
11
5
12
5
8
10
FORWARD-LEFT SIDE 9
12
S/N 0033-SUBS AND PRIOR AFT-RIGHT SIDE
BY MODIFICATION AND EARLY MODEL
FORWARD-LEFT SIDE
9G28-020B
1. BOLT 7. WASHER
2. WASHER 8. DUAL VENT/ROLLOVER VALVE
3. ELECTRICAL BONDING JUMPER 9. ORING
4. VENT TUBE ASSEMBLY 10. ELBOW DUCT
5. VENT HOSE 11. TRANSITION DUCT
6. BOLT 12. EDGE GROMMET
Figure 410. Dual Port Fuel Vent Float/Rollover Valve
Page 427
28-00-00 Original
12. Fuel Vent System Components (c). Disconnect elbow duct from transi
tion duct and fuel vent hose and
A. Fuel Vent Components Removal remove from bulkhead.
(Ref. Figure 411) B. Fuel Vent Components Installation
NOTE: This task is typical for Fuel Vent Sys (Ref. Figure 411)
tem Components removal.
NOTE: This task is typical for Fuel Vent Sys
Helicopter must be defueled be tem Components installation.
CAUTION fore floor panels A160, A170,
and/or A217 or both AL165 and AR165 are Consumable Materials
removed. Structural damage can occur if (Ref. CSPSPM)
any of these panels are removed with fuel in Item Nomenclature
the helicopter.
(1). Remove cabin floor panels AL155, C242 Adhesion Promoter
AR155, A160, AL165, AR165, A170, C432 Cleaner
A217, AL230, AR230 (Ref. Section C702 Lockwire
53-20-00) as required.
(1). Prepare fuel vent component surfaces
for electrical bonding (Ref. CSP-SPM).
(2). Install interconnect tube assemblies,
(2). Remove and discard lockwire and standpipe assemblies, and flame
disconnect fuel vent hoses from fuel arrestors, as required with bonding
vent float/rollover valve vent tubes, jumpers and remove bonding clamps,
interconnect tube assemblies, standpipe cushioned support clamps, and attach
assemblies, and flame arrestors, as ing hardware, as required. Torque
required. hardware as required.
CAUTION
Residual Fluids
(3). Disconnect bonding jumpers and completely cover bonding clamp and
remove bonding clamps, cushioned hardware on aft flame arrestor.
support clamps, and attaching hard
ware, as required, to remove intercon (4). Connect fuel vent hoses to float/rollover
nect tube assemblies, standpipe valve vent tubes, interconnect tube
assemblies, and flame arrestors, as assemblies, standpipe assemblies, and
required. flame arrestors, as required. Secure
with two to three turns of lockwire
(4). S/N 0033-subs - Remove forward left (C702).
vent ducts as required.
(5). S/N 0033-subs - Install forward left
(a). Remove sealing compound from vent ducts as required.
transition duct, elbow duct and
grommets. (a). Clean residual sealing compound
from transition duct, elbow duct,
(b). Disconnect transition duct from float/rollover valve, and grommets
float/rollover valve and elbow duct faying surfaces as required. Use
and remove from bulkhead. cleaner (C432).
Page 428
Original 28-00-00
(b). Lightly abrade faying surfaces. Use (f). Install transition duct and grommet
scouring pad (C817). through bulkhead, and connect to
float/rollover valve and elbow duct.
(c). Apply adhesion promoter (C242) to Allow sealing compound to cure
faying surfaces and allow to dry. before fueling aircraft.
NOTE: If necessary, float/rollover valve bolts
can be loosened to allow transition duct (6). Install cabin floor panels AL155,
installation. Retorque bolts after installa AR155, A160, AL165, AR165, A170,
tion. A217, AL230, AR230 (Ref. Section
53-20-00) as required.
(d). Apply sealing compound (C206) to
faying surfaces. (7). Perform fuel cell leak check/pressure
(e). Install elbow duct and grommet test (Ref. Section 28-00-00).
through bulkhead. Connect fuel vent
to elbow duct. Secure with lockwire (8). Fuel helicopter if necessary (Ref.
(C702). Section 12-00-00).
Page 429
28-00-00 Original
9 8
10
5
4
17
8
11
12
3 5
5 19
6
1
1
18
2
18
1
16
20
5
21 3
19
15
22
14
13
S/N 0033-SUBS AND PRIOR

BY MODIFICATION
9G28-005A
1. INTERCONNECT TUBE ASSEMBLY 12. NUT

2. STAND PIPE ASSEMBLY FWD 13. SCREW
3. FLAME ARRESTOR 14. WASHER
4. STAND PIPE ASSEMBLY AFT 15. CUSHIONED CLAMP
5. FUEL VENT HOSE 16. BRACKET ANGLE WITH NUT
6. FUEL VENT FAIRING 17. THREADED STANDOFF COMPOSITE BASE
7. SCREW 18. SINGLE VENT/ROLLOVER VALVE
8. WASHER 19. DUAL VENT/ROLLOVER VALVE
9. BONDING CLAMP 20. STAND PIPE ASSEMBLY FWD
10. BONDING JUMPER 21. TRANSITION DUCT
11. LOCKING WASHER 22. ELBOW DUCT
Figure 411. Fuel Vent System
Page 430
Original 28-00-00
13. Fuel Sump Drain Valve (2). Install fuel drain valve in fuel cell.
Torque drain valve.
A. Fuel Sump Drain Valve Removal
(Ref. Figure 412) (3). Insert forward drain control cable
assembly (3) or aft drain control cable
NOTE: This task is typical for LH and RH Fuel assembly (4) into drain valve. Install
Sump Drain Valve removal. bolt (7) washer (6) and clamp (5).
Torque bolt.
(4). Install rubber tubing (C608) (10) on
drain valve and secure with lockwire
(C702).
(1). Defuel helicopter (Ref. Section (5). Install sump access panel assembly
12-00-00). B178 (Ref. Section 06-00-00).
B178 (Ref. Section 06-00-00). (6). Fuel helicopter (Ref. Section 12-00-00).
(3). Remove and discard lockwire and (7). Visually check for leaks.
remove rubber tubing (C608) (10) from
fuel drain valve (9).
14. Fuel Sump Drain Valve Control Assembly
(4). Remove bolt (7), washer (6), and clamp (Fwd and Aft)
(5) retaining forward drain control
cable assembly (3) or aft drain control A. Fuel Sump Drain Valve Control Assembly
cable assembly (4). Remove cable end Removal
from fuel drain valve (9).
(Ref. Figure 412)
(5). Remove drain valve (9) from fuel cell
and discard O-ring (8).
NOTE: This task is typical for forward and aft
B. Fuel Sump Drain Valve Installation Fuel Sump Drain Valve Control Cable re
moval.
(Ref. Figure 412)
NOTE: This task is typical for LH and RH Fuel
B178 and open fuel drain access panel
Sump Drain Valve installation.
R185 (Ref. Section 06-00-00).
Consumable Materials (2). Remove bolt (7), washer (6), and clamp
(Ref. CSPSPM) (5) retaining forward drain control
Item Nomenclature cable assembly (3) or aft drain control
C109 Grease cable assembly (4).
C702 Lockwire
C608 Rubber Tubing (3). Remove control cable assembly plunger
from fuel drain valve (9).
Grease (C109) (4). Carefully remove sealing compound

from around flange of control cable
assembly.

(1). Lubricate O-ring (8) with grease from handle of control cable assembly
(C109) and install on fuel drain valve and remove cable assembly through
(9). guides and outer skin of helicopter.
Page 431
28-00-00 Original
B. Fuel Sump Drain Valve Control Assembly assembly (3) and aft drain control cable
Installation assembly (4). Torque bolt.
(Ref. Figure 412) Sealing Compound (C206)
NOTE: This task is typical for forward and aft

Fuel Sump Drain Valve Control Cable
installation.
(4). Apply sealing compound (C206) to form

Consumable Materials a fillet seal around control cable
(Ref. CSPSPM) assembly flange and helicopter skin
Item Nomenclature (Ref. CSP-SPM).
(5). Fasten control cable assembly to outer
skin of helicopter with screws (1) and
(1). Install control cable assembly (3) or (4) washers (2). Torque screws.
through outer skin and guides.
(6). Apply sealing compound (C206) over
(2). Install control cable assembly plunger heads of screws (Ref. CSP-SPM).
in fuel drain valve (9).
(7). Install sump access panel assembly
(3). Install clamp (5), bolt (7), and washer B178 and close fuel drain access panel
(6) to retain forward drain control cable R185 (Ref. Section 06-00-00).
2
(REF. FUSELAGE
STRUCTURE
1
4 155 - 165 in-lb 155 - 165 in-lb

17.5 - 18.6 Nm 17.5 - 18.6 Nm
1 8
9 9
2 8
5
3
6 6
7
7
10 10
9G28-017
1. SCREW 6. WASHER
2. WASHER 7. BOLT
3. FWD CONTROL CABLE ASSEMBLY 8. ORING
4. AFT CONTROL CABLE ASSEMBLY 9. DRAIN VALVE
5. CLAMP 10. RUBBER TUBING (C608)
Figure 412. Fwd and Aft Fuel Sump Drain Valve and Drain Valve Control Assembly
Page 432
Original 28-00-00
15. Fuel Cell Frangible Valve (10). Remove bolts (7) and washers (8)
attaching vapor shroud to keel beam
A. Fuel Cell Frangible Valve Removal and fuel cell.
(Ref. Figure 413) NOTE: During removal of frangible valve, take
precaution to retain gasket (14) between
NOTE: This task is typical for LH and RH Fuel fuel cell outlet fitting and keel beam.
Cell Frangible Valve removal.
(11). Remove vapor shroud (1) and spacer
Aviation Turbine Fuel (11) from frangible valve (3) hose
assembly.
(12). Disconnect fuel hose assembly (12)
ratchet end connector from frangible
valve (3) inside fuel cell. Pull back on
(1). Defuel helicopter (Ref. Section end to disengage ratchet, then unscrew.
12-00-00).
(2). Remove cabin seats, if applicable (Ref. attaching frangible valve (3) to fuel cell.
Section 25-20-00). Remove frangible valve from inside of
fuel cell and discard O-ring (13).
Section 25-20-00). B. Fuel Cell Frangible Valve Installation
(4). Remove cabin floor panels; AL165, (Ref. Figure 413)
AR165, A170, A217, AL230, AR230,
A235, AL250 and AR250 as required
(Ref. Section 53-20-00). Cell Frangible Valve installation.
CAUTION
(Ref. CSPSPM)
Residual Fluids Item Nomenclature
System Contamination C109 Grease
(5). Remove aft fuel cell access cover (Ref. C606 Rubber Tubing
Section 28-00-00). C702 Lockwire
fuel line vapor shroud (1). Disconnect (1). Prepare frangible valve surface for
vapor shroud hose from fuel intercon electrical bonding (Ref. CSP-SPM).
nect tee fitting vapor shroud box (2).
Grease (C109)
(7). Disconnect nut on frangible valve (3)
hose assembly from fuel interconnect
tee fitting (4).
(8). Remove and discard lockwire and
remove drain tubing connector (5) and
(C109) and install on frangible valve (3)
rubber tubing (C606) (6) from vapor
hose assembly.
shroud.
(3). Install frangible valve in fuel cell with
(9). On earlier serial number helicopters, hose through fuel cell.
sealing compound is applied. Carefully
remove sealing compound from fasten (4). Install fitting gasket (14) between fuel
ers and flange surfaces of frangible cell fitting and keel beam and install
valve flange junction with keel beam frangible valve hose assembly through
(Ref. CSP-SPM). keel beam.
Page 433
28-00-00 Original
(5). Install bolts (9) and washers (10) (10). Connect frangible valve (3) hose
attaching frangible valve to fuel cell. assembly to fuel interconnect tee fitting
Torque bolts. (4). Torque hose nut.
(6). Attach fuel hose assembly (12) ratchet Grease (C109)

end connector to frangible valve (3).
Tighten ratchet end connector hand
tight. Ratchets on hose and valve must
be fully engaged.
(11). Lightly lubricate shroud box tube end
(7). Install vapor shroud (1) and spacer (11) with grease (C109) and connect vapor
over frangible valve hose assembly. shroud hoses (1) to vapor shroud box (2)
and secure with two to three turns of
NOTE: lockwire (C702).
As an aid to installation, fabricate align (12). Install drain tubing connector (5) and
ment bolts (bullet bolts) by cutting heads rubber tubing (C606) (6) on vapor
off two 1/4 X 28 bolts 2 1/2 inches long and shroud (1). Secure drain tubing with
rounding off cut portion of bolt to form the lockwire (C702).
shape of a bullet.
(13). Install fuel cell access cover (Ref.
Install threaded portion of bullet bolt into
Section 28-00-00).
fuel cell exterior fitting top and bottom
hole. With fitting gasket (14) in place, (14). Install cabin floor panels AL165,
align bullet bolts in keel beam. Start bolts AR165, A170, A217, AL230, AR230,
(7) in threads and remove bullet bolts. A235, AL250 and AR250 as required
attaching vapor shroud to keel beam (15). Perform fuel cell leak check/pressure
and fuel cell. Torque bolts. test (Ref. Section 28-00-00).
Sealing Compound (C205) (16). Perform fuel supply vapor shroud leak
check/pressure test (Ref. Section
28-00-00).
(17). Install carpet, if applicable (Ref. Section
25-20-00).
(9). Apply sealing compound (C205) to (18). Install cabin seats, if applicable (Ref.
faying surfaces of vapor shroud and Section 25-20-00).
keel beam and heads of bolts (Ref.
CSP-SPM). (19). Fuel helicopter (Ref. Section 12-00-00).
Page 434
Original 28-00-00
2
902 CONFIG
HAND 9
TIGHTEN 10 11 3
12 4
REF. FUEL CELL
REF. KEEL BEAM

1
13
14
5
8
7
6
9G28-011
1. FUEL LINE VAPOR SHROUD 8. WASHER
2. VAPOR SHROUD BOX 9. BOLT
3. FRANGIBLE VALVE HOSE ASSEMBLY 10. WASHER
4. INTERCONNECT TEE FITTING 11. VAPOR SHROUD SPACER
5. DRAIN TUBING CONNECTOR 12. FUEL HOSE ASSEMBLY
6. RUBBER TUBING (C606) 13. ORING
7. BOLT 14. GASKET
Figure 413. Fuel Cell Frangible Valve
Page 435
28-00-00 Original
16. Fuel Interconnect Tee Fitting (10). Remove bolts (3) and washers (4)
attaching fuel interconnect tee fitting
A. Fuel Interconnect Tee Fitting Removal (10) to vapor shroud box (9). Remove
(Ref. Figure 414) fuel interconnect tee fitting.
B. Fuel Interconnect Tee Fitting Installation
Interconnect Tee Fitting removal. (Ref. Figure 414)
Aviation Turbine Fuel NOTE: This task is typical for LH and RH Fuel
Interconnect Tee Fitting installation.
(Ref. CSPSPM)
(1). Defuel helicopter (Ref. Section Item Nomenclature
12-00-00). C109 Grease
(2). Open baggage compartment door L262 C230 Sealant, Electrically Conductive
(Ref. Section 06-00-00). C702 Lockwire
(3). Remove cabin and baggage compart

ment floor panels AL165, AR165, A170, (1). Prepare vapor shroud box (9) and
A217, AL230, AR230, A235, AL250, interconnect tee fitting (10) surfaces for
AR250 as required (Ref. Section electrical bonding (Ref. CSP-SPM).
53-20-00). Sealant, Electrically Conductive (C230)
detach connector (1) from fuel pressure
switch assembly (12).
(5). Remove bolts (14) and washers (13) (2). Apply sealant (C230) to faying surface
from fuel interconnect vapor shroud box between vapor shroud box assembly (9)
cover assembly (2) and let cover hang and structure (Ref. CSP-SPM).
from wire bundle.
(3). Install fuel interconnect tee fitting (10)
in vapor shroud box (9) with bolts (3)
CAUTION and washers (4). Torque bolts.
Residual Fluids (4). 900CONFIG - Connect nut on fuel
System Contamination hose assembly (6), to fuel interconnect
tee fitting (10). Torque fuel hose nut.
(6). Remove pressure switch assembly (12)
from fuel interconnect tee fitting (10) (5). Connect nut on fuel tube assembly (5),
and discard O-ring (11). to fuel interconnect tee fitting (10).
Torque fuel tube nut.
disconnect vapor shroud hoses from (6). Connect nut on frangible valve hose (7)
vapor shroud box (9). to fuel interconnect tee fitting (10).
Torque frangible valve hose nut.
(8). Disconnect fuel hose assembly (6) (900
Grease (C109)
CONFIG), tube assembly (5), and
frangible valve hose assembly (7) from
fittings on interconnect tee fitting (10).
(9). 902 CONFIG - Remove and discard
lockwire, remove shroud box cap (17), (7). Lightly lubricate vapor shroud box tube
and remove tube fitting cap (18) from end with grease (C109) and connect
interconnect tee fitting, if replacing vapor shroud hoses to vapor shroud box
fitting. (9) and secure with lockwire (C702).
Page 436
Original 28-00-00
(8). 902 CONFIG - Install tube fitting cap 17. Fuel Pressure Switch Assembly
(18). Torque tube fitting cap. Install
shroud box cap (17) and secure with A. Fuel Pressure Switch Assembly Removal
lockwire (C702). (Ref. Figure 414)
(9). Lubricate O-ring (11) lightly with NOTE: This task is typical for LH and RH Fuel
grease (C109) and install on fuel Pressure Switch removal.
pressure switch assembly (12).
(10). Install fuel pressure switch assembly
(12) in fuel interconnect tee fitting (10).
Torque fuel pressure switch.
(11). Prepare vapor shroud box (9), vapor (1). Defuel helicopter (Ref. Section
shroud box cover assembly (2) surfaces 12-00-00).
for electrical bonding (Ref. CSP-SPM). (2). Open baggage compartment door L262
Sealant, Electrically Conductive (C230)
(3). Remove baggage compartment floor
panels A235, AL250, AR250 as re
quired (Ref. Section 53-20-00).
(12). Apply sealant (C230) to faying surfaces detach connector (1) from fuel pressure
between vapor shroud box cover and switch assembly (12).
vapor shroud box and install vapor (5). Remove bolts (14) and washers (13)
shroud box cover assembly (2) with from fuel interconnect vapor shroud
bolts (14) and washers (13). Torque cover assembly (2) and let cover hang
bolts. from wire bundle.
(13). Attach connector (1) and safety with
lockwire (C702). CAUTION
Residual Fluids
(14). Install cabin and baggage compartment
floor panels AL165, AR165, A170, System Contamination
A217, AL230, AR230, A235, AL250 as (6). Remove pressure switch assembly (12)
required (Ref. Section 53-20-00). with vapor shroud box cover (2) from
fuel interconnect tee fitting (10) and
(15). Perform fuel cell leak check/pressure discard O-ring (11).
(7). Remove silicone from back of connector.
(16). Perform fuel supply vapor shroud leak
Note color code and pin location
check/pressure test (Ref. Section CAUTION of wires when removing and
28-00-00).
install in same order to prevent switch mal
function.
(17). Close baggage compartment door L262
(Ref. Section 06-00-00). (8). Remove electrical pins from connector
with extraction tool (Ref. CSP-SPM,
(18). Fuel helicopter (Ref. Section 12-00-00). Section 20-60-00).
Page 437
B. Fuel Pressure Switch Assembly Grease (C109)

Installation
(Ref. Figure 414)

Pressure Switch installation. (3). Lubricate O-ring (11) lightly with
grease (C109) and install on fuel
pressure switch assembly (12).
(Ref. CSPSPM) (4). Install fuel pressure switch assembly
Item Nomenclature (12) with vapor shroud box cover (2) in
fuel interconnect tee fitting (10). Torque
C109 Grease fuel pressure switch.
C222 Fluorosilicone Compound
C230 Sealant, Electrically Conductive
C702 Lockwire
C818 Sleeve, Protective, Expandable and
Insulating
C819 Insulation Sleeving, Electrical, Heat (5). Apply sealant (C230) to faying surfaces
Shrinkable between vapor shroud cover and vapor
shroud box and install fuel vapor
shroud box cover assembly (2) with
(1). Install switch wires in connector. bolts (14) and washers (13). Torque
(a). Install expandable sleeving (C818) bolts.
over wires. (6). Attach connector (1), and safety with
lockwire (C702).
(b). Install heat shrinkable sleeving
(C819) on wires and shrink over NOTE: Allow sealant (C230) to fully cure prior
electrical pin splices. to pressure test.
(c). Install electrical pins in connector (7). Perform fuel cell leak check/pressure
with insertion tool (Ref. CSP-SPM, test (Ref. Section 28-00-00).
Section 20-60-00).
Fluorosilicone Compound (C222) check/pressure test (Ref. Section
28-00-00).
(10). Perform fuel booster pump operational
(d). Apply fluorosilicone compound (C222)
to back of connector and wires and (11). Install baggage compartment floor
allow to cure. panels; A235, AL250, AR250 (Ref.
Section 53-20-00).
(2). Prepare vapor shroud box (9) and vapor
shroud box cover (2) surface for electri (12). Close baggage compartment door L262
cal bonding (Ref. CSP-SPM). (Ref. Section 06-00-00).
Page 438
18 5
17
2
3 15 1
4
8 902 CONFIG
13 14
11 12
10
95 - 105 in-lb
7 9 10.7 - 11.9 Nm
16
9G28-010
1. CONNECTOR (P350 RH, P351 LH) 10. FUEL INTERCONNECT TEE FITTING
2. VAPOR SHROUD BOX COVER ASSEMBLY 11. ORING
3. BOLT 12. FUEL PRESSURE SWITCH ASSEMBLY
5. TUBE ASSEMBLY 14. BOLT
6. FUEL HOSE 15. CONNECTOR JAM NUT
7. FUEL HOSE FRANGIBLE VALVE 16. RUBBER TUBING (C606)
8. FRANGIBLE VALVE 17. SHROUD BOX CAP
9. VAPOR SHROUD BOX ASSEMBLY 18. TUBE FITTING CAP
Figure 414. Fuel Interconnect Tee Fitting and Fuel Pressure Switch
18. Fuel ShutOff Valve Assembly (3). Remove left Electronic Engine Control
(EEC) (Ref. Section 76-00-00).
A. Fuel ShutOff Valve Assembly Removal
(4). Lower or remove left hand hinged
(Ref. Figure 415) avionics shelf (Ref. Section 25-70-00).
NOTE: This task is typical for LH and RH Fuel (5). Remove and discard lockwire and
Shut-Off Valve Assembly removal. detach connector (1) from fuel shut-off
valve assembly (8).
attaching vapor shroud cover assembly
(4) to vapor shroud box (5). Let cover
hang from wire bundle.
Make sure shut-off valve is in CAUTION

CAUTION OPEN position. Take precau
tions to catch residual fuel when removing Residual Fluids
shut-off valve. System Contamination
(1). Open baggage compartment door L262 (7). Disconnect tube assemblies (6 and 7)
(Ref. Section 06-00-00). from fittings on fuel shut-off valve
assembly (8).
(2). Remove baggage compartment interior
trim roof insulation panel (Ref. Section (8). Remove bolts (9) and washers (10)
25-50-00). attaching fuel shut-off valve (8) to
Page 439
28-00-00 Original
vapor shroud box (5) and remove fuel Fluorosilicone Compound (C222)
shut-off valve assembly with vapor
shroud cover (4).
(9). Remove silicone from back of connector.

(d). Apply fluorosilicone compound (C222)
to back of connector and wires and
Note color code and pin location allow to cure.
CAUTION of wires when removing and
install in same order to prevent valve mal (2). Prepare vapor shroud box (5) and fuel
function. shut-off valve (8) surface for electrical
(10). Remove electrical pins from connector Sealant, Electrically Conductive (C230)
with extraction tool (Ref. CSP-SPM,
Section 20-60-00).
B. Fuel ShutOff Valve Assembly

Installation (3). Apply sealant (C230) to faying surface
between vapor shroud box assembly (5)
and structural bulkhead (Ref. CSP-
(Ref. Figure 415) SPM).
NOTE: This task is typical for LH and RH Fuel (4). Install fuel shut-off valve assembly (8)
Shut-Off Valve Assembly installation. in vapor shroud box (5) with bolts (9)
and washers (10). Torque bolts.
(5). Connect tube assemblies (6 and 7) to
Consumable Materials fittings on fuel shut-off valve assembly
(Ref. CSPSPM) (8). Torque tube nuts.
Item Nomenclature
(6). Prepare vapor shroud box (5) and vapor
C222 Fluorosilicone Compound shroud box cover (4) surface for electri
C230 Sealant, Electrically Conductive cal bonding (Ref. CSP-SPM).
C702 Lockwire (7). Apply sealant (C230) to faying surfaces
C818 Sleeve, Protective, Expandable and between vapor shroud box cover and
Insulating vapor shroud box and install vapor
C819 Insulation Sleeving, Electrical, Heat
Shrinkable
(8). Attach connector (1) to fuel shut-off
valve assembly and safety with lock
(1). Install valve wires in connector. wire (C702).
(9). Perform fuel shut-off valve operational
(a). Install expandable sleeving (C818) test (Ref. Section 28-00-00).
over wires.
(10). Perform fuel booster pump operational
test (Ref. Section 28-00-00) and check
(b). Install heat shrinkable sleeving for fuel leakage.
(C819) on wires and shrink over
electrical pin splices. NOTE: Allow sealant (C230) to fully cure prior
to pressure test.
(c). Install electrical pins in connector (11). Perform fuel supply vapor shroud leak
with insertion tool (Ref. CSP-SPM, check/pressure test (Ref. Section
Section 20-60-00). 28-00-00).
Page 440
(12). Install left hand hinged avionics shelf 19. Crossfeed Fuel ShutOff Valve (900
(Ref. Section 25-70-00). CONFIG)
A. Crossfeed Fuel ShutOff Valve Assembly
(13). Install Electronic Engine Control (EEC) Removal
(14). Install baggage compartment interior
25-50-00).

(15). Close baggage compartment door L262 12-00-00).
(2). Open baggage compartment door L262
7 (3). Remove baggage compartment floor
panels; A235, AL250, AR250 (Ref.
3 2 Section 53-20-00).
11
detach connector (1) from crossfeed fuel
shut-off valve cover assembly (8).
attaching crossfeed fuel shut-off valve
1
cover assembly (8) to vapor shroud box
(10). Let cover assembly hang from
wire bundle.
4
9
5 8 10 CAUTION
6 Residual Fluids
9G28-021 System Contamination
1. CONNECTOR (P353)
2. BOLT (6). Disconnect hose assemblies (6 and 7)
3. WASHER
from fittings on crossfeed fuel shut-off
4. VAPOR SHROUD COVER ASSEMBLY
5. VAPOR SHROUD BOX ASSEMBLY valve assembly (9).
6. TUBE ASSEMBLY
7. TUBE ASSEMBLY (7). Remove bolts (4) and washers (5)
8. FUEL SHUTOFF VALVE ASSEMBLY attaching crossfeed fuel shut-off valve
9. BOLT assembly to vapor shroud box (10) and
10. WASHER remove crossfeed fuel shut-off valve
11. CONNECTOR JAM NUT
assembly.
Figure 415. Fuel ShutOff Valve Assembly (8). Remove silicone from back of connector.
Page 441
Note color code and pin location Sealant, Electrically Conductive (C230)
CAUTION of wires when removing and
install in same order to prevent valve mal
function.
(9). Remove electrical pins from connector

with extraction tool (Ref. CSP-SPM, (3). Apply sealant (C230) to faying surface
Section 20-60-00). between vapor shroud box assembly
(10) and structure (Ref. CSP-SPM).
B. Crossfeed Fuel ShutOff Valve Assembly
Installation (4). Install crossfeed fuel shut-off valve
assembly (9) in vapor shroud box (10)
(Ref. Figure 416) with bolts (4) and washers (5). Torque
bolts.
Consumable Materials (5). Connect hose assemblies (6 and 7) to
(Ref. CSPSPM) fittings on crossfeed fuel shut-off valve
Item Nomenclature assembly (9). Torque hose nuts.
C222 Fluorosilicone Compound
C230 Sealant, Electrically Conductive (6). Prepare vapor shroud box (10) and
C702 Lockwire
vapor shroud box cover (8) surface for
electrical bonding (Ref. CSP-SPM).
C818 Sleeve, Protective, Expandable and
Insulating
(7). Apply sealant (C230) to faying surfaces
C819 Insulation Sleeving, Electrical, Heat between vapor shroud box cover and
Shrinkable vapor shroud box and install vapor
(1). Install valve wires in connector.
(8). Attach connector (1) to crossfeed fuel
(a). Install expandable sleeving (C818) shut-off valve assembly and safety
over wires. with lockwire (C702).
(b). Install heat shrinkable sleeving (9). Perform operational test of crossfeed
(C819) on wires and shrink over fuel shut-off valve (Ref. Section
electrical pin splices. 28-00-00).
(c). Install electrical pins in connector NOTE: Allow sealant (C230) to fully cure prior
with insertion tool (Ref. CSP-SPM, to pressure test.
Section 20-60-00).
Fluorosilicone Compound (C222)
test and fuel supply vapor shroud leak
check / pressure test (Ref. Section
28-00-00).
(11). Install baggage compartment floor

(d). Apply fluorosilicone compound (C222) panels; A235, AL250, AR250 (Ref.
to back of connector and wires and Section 53-20-00).
allow to cure.
(2). Prepare vapor shroud box (10) and
crossfeed shut-off valve (9) surface for (13). Close baggage compartment door L262
electrical bonding (Ref. CSP-SPM). (Ref. Section 06-00-00).
Page 442
access door assembly L210 or R210

6
3
2 (Ref. Section 06-00-00).
1 (2). 902 CONFIG - Open lower transmis
5 4 sion access door assembly L210 or R210
(3). Remove cabin roof panels (Ref. Section
25-20-00).
11 CAUTION
9
7
Residual Fluids
10
8 System Contamination
(4). 900CONFIG - Disconnect male
9G28-009 ratcheting fitting of engine fuel feed
1. CONNECTOR (P355) hose (1) from frangible valve (2) fitting.
2. BOLT Pull back on end to disengage ratchet,
3. WASHER then unscrew.
4. BOLT
5. WASHER (5). 902 CONFIG - Disconnect engine fuel
6. HOSE ASSEMBLY
7. HOSE ASSEMBLY
feed hose.
8. VAPOR BOX COVER ASSEMBLY
9. FUEL SHUT OFF CROSSFEED VALVE ASSEMBLY
(a). Remove and discard lockwire from
10. VAPOR SHROUD BOX ASSEMBLY engine fuel feed hose vapor shroud
11. CONNECTOR JAM NUT hose. Disconnect engine fuel feed
Figure 416. Crossfeed Fuel ShutOff Valve hose vapor shroud hose.
(900 CONFIG) (b). Remove and discard lockwire from
engine fuel feed hose nut. Disconnect
20. Engine Deck Frangible Valve engine fuel feed hose from frangible
A. Engine Deck Frangible Valve Removal valve.
(Ref. Figure 417) (6). Carefully remove sealing compound

covering fasteners and flange surfaces
NOTE: This task is typical for LH and RH En (Ref. CSP-SPM).
gine Deck Frangible Valve removal.
NOTE: Vapor shroud box cover drain hose can
Aviation Turbine Fuel remain connected.
vapor shroud cover assembly.
(8). Disconnect nut on fuel tube (6) from
Make sure shut-off valve is in fitting on frangible valve (2).
CAUTION OPEN position. Take precau
tions to catch residual fuel when removing (9). Remove bolts (7) washers (8) and
frangible valve. remove frangible valve from top of
engine deck. Remove and discard
(1). 900CONFIG - Open transmission O-ring (9).
Page 443
B. Engine Deck Frangible Valve Installation Sealing Compound (C207)

(Ref. Figure 417)
NOTE: This task is typical for LH and RH En
gine Deck Frangible Valve installation.
Release Agent (C417)
(Ref. CSPSPM)
Item Nomenclature
C109 Grease
C207 Sealing Compound, Fuel Resistant (7). Verify the integrity of sealing compound
C417 Release Agent
(C207) seal on vapor shroud box flanges
(part of fuselage structure). If there are
C702 Lockwire voids in seal, repair or replace as
follows:
Grease (C109)
(a). Apply sealing compound (C207) to
vapor shroud box flanges as required.
Ensure that sealing compound does
not enter fastener holes or nutplates.
(1). Lubricate O-ring (9) with grease (b). Apply release agent (C417) to vapor
(C109) and install on frangible valve shroud box cover assembly (3).
(2).
(c). Allow sealant time to set up before
(2). Install frangible valve in engine deck installing fasteners.
with bolts (7) and washers (8). Torque
bolts. (d). Install vapor shroud box cover
assembly (3) with bolts (4) and
(3). Connect nut on fuel tube (6), to fitting washers (5). Torque bolts.
on frangible valve (2). Torque fuel tube
nut. NOTE: Allow sealing compound (C207) to fully
cure prior to pressure test. Cure time is 72
(4). 900CONFIG - Connect male ratchet
hours at 70-80F (21-27C). Elevated tem
ing fitting on engine fuel feed hose (1).
peratures up to 130F (54C) may be used
Torque fitting hand tight. Ratchets on
to shorten cure time.
hose and valve must be fully engaged.
(5). 902 CONFIG - Connect engine fuel (8). Perform fuel supply vapor shroud leak
feed hose. check/pressure test (Ref. Section
28-00-00).
(a). Connect engine fuel feed hose to
frangible valve fitting. Torque hose (9). Install ceiling panels in cabin (Ref.
nut and safety with lockwire (C702). Section 25-20-00).
(b). Connect engine fuel feed hose vapor (10). 900CONFIG - Close transmission
shroud hose and secure with lockwire access door assembly L210 or R210
(C702). (Ref. Section 06-00-00).
(6). Perform fuel booster pump operational (11). 902 CONFIG - Close lower transmis
test (Ref. Section 28-00-00) and check sion access door assembly L210 or R210
for fuel leakage. (Ref. Section 06-00-00).
Page 444
7 HAND
1 TIGHTEN HAND
1
TIGHTEN
8 7
2
8 2
6
3
3
5 (REF. FUSELAGE 6 5
4 STRUCTURE)
RIGHT HAND LEFT HAND 4
(REF. FUSELAGE
STRUCTURE)
9G28-007A
1. MALE RATCHETING FITTING 6. FUEL TUBE/LINES
2. ENGINE DECK FRANGIBLE VALVE 7. BOLT
3. VAPOR SHROUD COVER ASSEMBLY 8. WASHER
4. BOLTS 9. ORING
5. WASHER
Figure 417. Engine Deck Frangible Valves (900 CONFIG)
Page 445
28-00-00 Original
21. Engine Fuel Feed Hose (f). Remove and discard lockwire from
vapor shroud hose (4). Disconnect
A. Engine Fuel Feed Hose Removal vapor shroud hose.
(Ref. Figure 418) (g). Remove and discard lockwire and

disconnect lower end of engine fuel
NOTE: This task is typical for LH and RH En feed hose (3) from frangible valve (2)
gine Fuel Feed Hose removal. fitting.
(h). Disconnect upper end of fuel feed
hose assembly from engine driven
fuel pump elbow fitting.
(i). Remove fuel feed hose assembly with
vapor shroud hose and spacers.
Make sure shut-off valve is in (j). Remove vapor shroud hose and
CAUTION OPEN position. Take precau spacers from fuel feed hose assembly.
tions to catch residual fuel when removing
engine feed hose. B. Engine Fuel Feed Hose Installation
(1). 900 CONFIG - Remove engine fuel (Ref. Figure 418)

feed hose.
NOTE: This task is typical for LH and RH En
gine Fuel Feed Hose installation.
(a). Open transmission access door
assembly L210 or R210 (Ref. Section
06-00-00). Consumable Materials
(Ref. CSPSPM)
(b). Disconnect male ratcheting fitting of Item Nomenclature
engine fuel feed hose (1) from frangi C207 Sealing Compound, Fuel Resistant
ble valve (2) fitting. Pull back on end
C702 Lockwire
to disengage ratchet, then unscrew.
(c). Remove and discard lockwire and (1). 900 CONFIG - Install engine fuel feed
disconnect fuel feed hose assembly hose.
from engine driven fuel pump elbow
fitting. (a). Connect fuel feed hose (1) to engine
driven fuel pump elbow fitting.
(2). 902 CONFIG - Remove engine fuel Torque fuel feed hose nut and safety
feed hose. with lockwire (C702).
(a). Open upper and lower transmission (b). Connect engine fuel hose (1) male
access door assembly L210 or R210 ratcheting fitting to frangible valve
(Ref. Section 06-00-00). fitting (2). Torque fitting hand tight.
Ratchets on hose and valve must be
(b). Remove aft swashplate fairing fully engaged.
(c). Perform fuel booster pump operation
al test (Ref. Section 28-00-00) and
(c). Remove screws attaching FMU vapor
check for fuel leakage.
shroud box (5) to FMU connector.
(d). Close transmission access door
(d). Remove and discard lockwire and assembly L210 or R210 (Ref. Section
disconnect vapor shroud duct from 06-00-00).
top of FMU vapor shroud box.
(2). 902 CONFIG - Install engine fuel feed
(e). Open FMU vapor shroud box. hose.
Page 446
Original 28-00-00
(a). Install spacers on fuel feed hose (3) (f). Perform fuel booster pump operation
al test (Ref. Section 28-00-00) and
Sealing Compound (C207) check for fuel leakage.
(g). Connect vapor shroud hose and
secure with lockwire (C702).
(h). Close FMU vapor shroud box (5).
(b). Apply a fillet of sealing compound (i). Install screws attaching FMU fuel
(C207) at junction of spacer and hose. shroud box to FMU connector.
not block holes in spacer. (j). Connect vapor shroud duct to top of
FMU vapor shroud box. Secure vapor
(c). Install vapor shroud hose (4) over shroud duct with lockwire (C702).
fuel feed hose and spacers.
(k). Perform fuel supply vapor shroud
(d). Connect upper end of fuel feed hose leak check/pressure test (Ref. Section
to engine driven fuel pump elbow 28-00-00).
fitting. Torque fuel feed hose nut. (l). Install aft swashplate fairing assem
bly (Ref. Section 53-30-00).
(e). Connect lower end of fuel feed hose to
frangible valve fitting. Torque fuel (m). Close upper and lower transmission
feed hose nut and safety with lock access door assembly L210 or R210
wire (C702). (Ref. Section 06-00-00).
5
LEFT ENGINE
LOOKING INBOARD
2
902 CONFIG
3
4
902 CONFIG
9G28-044A
1. ENGINE FUEL FEED HOSE ASSEMBLY (900 CONFIG) 4. ENGINE FUEL FEED VAPOR SHROUD HOSE (902
2. ENGINE DECK FRANGIBLE VALVE CONFIG)
3. ENGINE FUEL FEED HOSE ASSEMBLY (902 CONFIG) 5. FMU FUEL SHROUD BOX (902 CONFIG)
Figure 418. Engine Fuel Feed Hose
Page 447
28-00-00 Original
22. Fuel Supply Tubes, Hoses and Shrouds (a). Remove and discard lockwire.
Disconnect LH or RH vapor shroud
A. Fuel Supply Tubes, Hoses and Shrouds hose (1, 2), from LH or RH fuel
Removal interconnect tee fitting vapor shroud
(Ref. Figure 419) box (3, 4), and LH or RH fuel shut-
off valve vapor shroud box (5, 6).
NOTE: This task is typical for LH and RH fuel
supply tube, hoses, and shrouds. (b). Pull vapor shroud hose back and
disconnect upper end of LH or RH
Aviation Turbine Fuel engine feed tube assembly (7, 8) from
union (12).
(c). Disconnect lower end of LH or RH
engine feed tube assembly (7, 8) from
LH or RH fuel interconnect tee fitting
CAUTION (9, 10).
(d). Remove pan head bolt (13),washers
Residual Fluids
(14) and nut (15) and remove cush
System Contamination ioned support clamp (16). Remove
engine feed tube assembly with
(1). Defuel helicopter if necessary (Ref.
vapor shroud hose.
Section 12-00-00).
NOTE: Note location of spacers on tube assem
(2). Gain access to components, as required.
bly before removal. Replace spacers in same
(a). Open baggage compartment door location upon installation.
L262 (Ref. Section 06-00-00). (e). Slide LH or RH vapor shroud hose (1,
(b). Remove baggage compartment roof 2) off of engine feed tube assembly
panels (Ref. Section 25-50-00). and remove vapor shroud spacers
(17) from tube assembly.
(c). Remove Electronic Engine Control
(EEC) (Ref. Section 76-00-00). B. Fuel Supply Tubes, Hoses and Shrouds
Installation
(d). Remove hinged avionics shelf (Ref.
Section 25-70-00). (Ref. Figure 419)
(e). Remove electrical load center (Ref. NOTE: This task is typical for LH and RH fuel
CSP-900RMM-3, Section 96-00-00). supply tube, hoses and shrouds.
(f). Remove baggage compartment floor Consumable Materials

panels A235, AR250, AL250 (Ref. (Ref. CSPSPM)
(3). Remove bolts (19) and washers (18) C109 Grease
from vapor shroud box cover assem C207 Sealing Compound, Fuel Resistant
blies: C230 Sealant, Electrically Conductive
(a). LH tee fitting vapor shroud box (3). C702 Lockwire
(b). LH fuel shut-off valve vapor shroud

box (5). (1). Install fuel supply tube.
(c). RH tee fitting vapor shroud box (4). NOTE: Orient spacer slot down on horizontal
runs or aft on vertical runs. Ref. Figure 420
(d). RH fuel shut-off valve vapor shroud for spacer locations.
box (6).
(a). Install spacers (17) on LH or RH
(4). Remove fuel supply tube. engine feed tube assembly (7, 8).
Page 448
Original 28-00-00
Sealing Compound (C207) shroud box cover assembly with bolts

(19) and washers (18). Torque bolts.
(4). Fuel helicopter if necessary (Ref.
Section 12-00-00).
(b). Apply a fillet of sealing compound (5). Install electrical load center (Ref.
(C207) at junction of spacer and tube. CSP-900RMM-3, Section 96-00-00).
(6). Install hinged avionic shelf (Ref.
not block holes in spacer.
Section 25-70-00).
(c). Slide LH or RH vapor shroud hose (1, (7). Install Electronic Engine Control (EEC)
2) over tube assembly and spacers. (Ref. Section 76-00-00).
(d). Install LH or RH engine feed tube (8). Perform fuel booster pump operational
assembly (7, 8) and connect lower test (Ref. Section 28-00-00) and check
end to LH or RH fuel interconnect tee for fuel leakage.
fitting (9, 10). Torque tube nuts.
(e). Connect upper end of LH or RH check/pressure test (Ref. Section
engine feed tube assembly (7, 8) to 28-00-00).
union (12). Torque tube nuts.
(10). Close access as required.
Grease (C109)
(a). Install baggage compartment floor
panels A235, AR250, AL250 (Ref.
Section 53-20-00).
(b). Install baggage compartment roof
(f). Lightly lubricate outside surface of panels (Ref. Section 25-50-00).
beaded tube ends with grease (C109).
(c). Close baggage compartment door
(g). Connect LH or RH vapor shroud hose L262 (Ref. Section 06-00-00).
(1, 2) to LH or RH fuel shut-off valve
vapor shroud box (3, 4) and LH or 23. Lower Fuel Supply Hoses and Shrouds
RH fuel interconnect tee fitting vapor (900 CONFIG)
shroud box (5, 6). Secure vapor A. Lower Fuel Supply Hoses and Shrouds
shroud hose with lockwire (C702). Removal
(h). Install cushioned support clamp (16) (Ref. Figure 419)
around tube assembly vapor shroud
hose at location of center spacer with NOTE: This task is typical for LH and RH low
pan head bolt (13), washers (14) and er fuel supply hoses and shrouds.
nut (15). Torque nut.

12-00-00).
(2). Prepare vapor shroud box and vapor
shroud box cover surface for electrical (2). Open baggage compartment door L262.
bonding (Ref. CSP-SPM). (Ref. Section 06-00-00).
(3). Apply sealant (C230) to faying surfaces (3). Remove baggage compartment floor
between vapor shroud box cover and panels A235, AR250, AL250 (Ref.
vapor shroud box and install vapor Section 53-20-00).
Page 449
28-00-00 Revision 1
(4). Remove lower fuel supply hose.

(a). Remove vapor shroud box cover (Ref. CSPSPM)
assemblies from LH or RH intercon Item Nomenclature
nect tee fitting and crossfeed shut-off C207 Sealing Compound, Fuel Resistant
valve (Ref. Section 28-00-00). C230 Sealant, Electrically Conductive
C702 Lockwire
(b). Remove and discard lockwire.
Disconnect LH or RH vapor shroud
hose (21, 22) from LH or RH inter (1). Install lower fuel supply hose.
connect tee fitting vapor shroud box
(3, 4) and fuel crossfeed shut-off NOTE: Orient spacer slot down on horizontal
valve shroud box (11). runs or aft on vertical runs.
(a). Install spacers (17) on LH or RH fuel

CAUTION supply hose assembly (23, 24). Ref.
Figure 420 for spacer locations.
Residual Fluids
(c). Pull vapor shroud hose back and

disconnect end of LH or RH fuel
supply hose assembly (23, 24) from
LH or RH interconnect tee fitting (9, (b). Apply a fillet of sealing compound
10). (C207) at junction of spacer and hose.
(d). Disconnect LH or RH fuel supply not block holes in spacer.
hose assembly (23, 24) from crossfeed
shut-off valve (20). (c). Slide LH or RH vapor shroud hose
(21, 22) over LH or RH hose assem
bly (23, 24) and spacers (17).
(e). Remove bolt (25), washers (14) and
nut (15) and remove cushioned (d). Install LH or RH fuel supply hose
support clamp (16). Remove fuel assembly (23, 24) and connect to LH
supply hose assembly with vapor or RH interconnect tee fitting (9, 10).
shroud hose from aircraft. Torque hose fittings (Ref. CSP-SPM).
NOTE: Note location of spacers on hose assem (e). Connect LH or RH fuel supply hose
bly before removal. Replace spacers in same assembly (23, 24) to crossfeed
location upon installation. shut-off valve (20). Torque hose
fittings (Ref. CSP-SPM).
(f). Slide LH or RH vapor shroud hose
(21, 22) off of LH or RH hose assem (f). Connect LH or RH vapor shroud hose
bly (23, 24) and remove vapor shroud (21, 22) to crossfeed shut-off valve
spacers (17) from hose assembly. vapor shroud box (11) and LH or RH
interconnect tee fitting vapor shroud
box (3, 4). Secure vapor shroud hose
B. Lower Fuel Supply Hoses and Shrouds
with lockwire (C702).
Installation
(g). Install cushioned support clamp (16)
(Ref. Figure 419) around fuel supply vapor shroud hose
at location of center spacer with bolt
NOTE: This task is typical for LH and RH low (25), washers (14) and nut (15).
er fuel supply hoses and shrouds. Torque nut (Ref. CSP-SPM).
Page 450
Revision 1 28-00-00
(2). Prepare vapor shroud box and vapor (2). Open baggage compartment door L262.
shroud box cover surface for electrical (Ref. Section 06-00-00).
Sealant, Electrically Conductive (C230) panels A235, AR250, AL250 (Ref.
Section 53-20-00).
(4). Remove supplemental fuel tank (Ref.
Section 28-10-00)
(5). Remove forward supplemental fuel
(3). Apply sealant (C230) to faying surfaces tank foam supports (Ref. Section
between vapor shroud box cover and 28-10-00).
vapor shroud box and install vapor
(6). Remove lower fuel supply hose.
shroud box cover assembly with bolts
(19) and washers (18). Torque bolts. (a). Remove vapor shroud box cover
assemblies from LH or RH intercon
(4). Perform fuel cell leak check/pressure nect tee fitting (Ref. Section
test (Ref. Section 28-00-00). 28-00-00).
(5). Perform fuel supply vapor shroud leak (b). Remove and discard lockwire.
check/pressure test (Ref. Section Disconnect LH or RH vapor shroud
28-00-00). hose (21, 22) from LH or RH inter
connect tee fitting vapor shroud box
(6). Install baggage compartment floor (3, 4).
panels A235, AR250, AL250 (Ref.
(c). Remove sealant from vapor shroud at
Section 06-00-00).
keel beam.
(7). Close baggage compartment door L262
(Ref. Section 06-00-00). CAUTION
(8). Fuel helicopter (Ref. Section 12-00-00). Residual Fluids

24. Lower Fuel Supply Hoses and Shrouds, (d). Pull vapor shroud hose back and
Supplemental Fuel System (Option) disconnect end of LH or RH fuel
(900 CONFIG) supply hose assembly (23, 24) from
LH or RH interconnect tee fitting (9,
A. Lower Fuel Supply Hoses and Shrouds, 10).
Supplemental Fuel System, Removal
(e). Disconnect LH or RH fuel supply
(Ref. Figure 419) hose assembly (23, 24) from crossfeed
shut-off valve (20).
NOTE:
(f). Remove bolt (25), washers (14) and
The supplemental fuel system installa nut (15) and remove cushioned
tion removes the vapor shroud box instal support clamp (16). Remove fuel
lation at the crossfeed valve. supply hose assembly with vapor
This task is typical for LH and RH lower shroud hose from aircraft.
fuel supply hoses and shrouds with sup (g). Remove and discard tiedown strap
plemental fuel system installation. (28) and remove grommet (29).
Aviation Turbine Fuel NOTE: Note location of spacers on hose assem
bly before removal. Replace spacers in same
location upon installation.
(h). Slide LH or RH vapor shroud hose
(21, 22) off of LH or RH hose assem
(1). Defuel supplemental fuel tank (Ref. bly (23, 24) and remove vapor shroud
Section 12-00-00). spacers (17) from hose assembly.
Page 451
28-00-00 Revision 1
B. Lower Fuel Supply Hoses and Shrouds, (g). Install cushioned support clamp (16)
Supplemental Fuel System, Installation around fuel supply vapor shroud hose
at location of center spacer with bolt
(Ref. Figure 419) (25), washers (14) and nut (15).
Torque nut (Ref. CSP-SPM).
NOTE: This task is typical for LH and RH low
er fuel supply hoses and shrouds. Sealing Compound (C205)
(Ref. CSPSPM)
Item Nomenclature
C207 Sealing Compound, Fuel Resistant (h). Install modified grommet (29) into
end of vapor shroud with shroud
positioned onto hose end fitting.
C230 Sealant, Electrically Conductive Install wet with sealing compound
C702 Lockwire (C205). Secure grommet with strap
(28).
(1). Install lower fuel supply hose. (2). Seal vapor shroud hose at keel beam
with sealing compound (C205). Ensure
NOTE: Orient spacer slot down on horizontal opening is entirely closed to provide a
runs or aft on vertical runs. vapor tight seal.
(a). Install spacers (17) on LH or RH fuel (3). Prepare vapor shroud box and vapor
supply hose assembly (23, 24). Ref. shroud box cover surface for electrical
Figure 420 for spacer locations. bonding (Ref. CSP-SPM).
Sealing Compound (C207) Sealant, Electrically Conductive (C230)
(b). Apply a fillet of sealing compound (4). Apply sealant (C230) to faying surfaces
(C207) at junction of spacer and hose. between vapor shroud box cover and
Ensure that sealing compound does vapor shroud box and install vapor
not block holes in spacer. shroud box cover assembly with bolts
(19) and washers (18). Torque bolts
(c). Slide LH or RH vapor shroud hose
(Ref. CSP-SPM).
(21, 22) over LH or RH hose assem
bly (23, 24) and spacers (17). (5). Perform supplemental fuel tank leak
check/pressure test (Ref. Section
(d). Install LH or RH fuel supply hose
28-10-00).
assembly (23, 24) and connect to LH
or RH interconnect tee fitting (9, 10). (6). Perform fuel supply vapor shroud leak
Torque hose fitting (Ref. CSP-SPM). check/pressure test (Ref. Section
28-00-00).
(e). Connect LH or RH fuel supply hose
assembly (23, 24) to crossfeed (7). Install baggage compartment floor
shut-off valve (20). Torque hose panels A235, AR250, AL250 (Ref.
fitting (Ref. CSP-SPM). Section 06-00-00).
(f). Connect LH or RH vapor shroud hose (8). Close baggage compartment door L262
(21, 22) to LH or RH interconnect tee (Ref. Section 06-00-00).
fitting vapor shroud box (3, 4).
Secure vapor shroud hose with (9). Fuel supplemental fuel tank (Ref.
lockwire (C702). Section 12-00-00).
Page 452
Revision 1 28-00-00
19
18
12
5 7 (LH)
8 (RH)
17
2 1 15
14
4 13
14
16
24 22
21
7 (LH)
8 (RH)
23
900 CONFIG - PW206A
11 3
18 19
20
9 (LH)
19 10 (RH)
18
900 CONFIG - PW206A
25
14
15
16
17
23
23
14
900 CONFIG - PW206A

9G28-025-1C
Figure 419. Fuel Supply Tubes, Hoses and Shrouds (Sheet 1 of 3)
Page 453
902 CONFIG,
900 CONFIG - PW206E
900 CONFIG - PW207E
27
26
9G28-025-2A
Page 454
28 (2 PL) 29 (2 PL)
(NOTE 5)
30
(NOTE 1)
32
33 (2 PL)
34
(NOTE 2)
(NOTE 1)
31
(NOTE 3)
4)
(NOTE 1)
(NOTE 1)
(NOTE 4)
900 CONFIG WITH SUPPLEMENTAL FUEL SYSTEM

NOTES:
1. FUEL COMPARTMENT OVERBOARD VENT AND ALL REMOVABLE HARDWARE IS REMOVED.
2. PREPARED FOR ELECTRICAL BOND.
3. SEALANT.
4. CROSSFEED VALVE SHROUD BOX, BOX COVER, BOX DRAIN, AND ALL REMOVABLE HARDWARE IS REMOVED.
5. ONE FLANGE OF GROMMET IS REMOVED. 9G28-025-3
Page 455
28-00-00 Revision 1

1. LH VAPOR SHROUD HOSE 20. CROSSFEED SHUTOFF VALVE
2. RH VAPOR SHROUD HOSE (900 CONFIG PW206A)
3. LH INTERCONNECT TEE FITTING VAPOR SHROUD 21. LOWER LH VAPOR SHROUD HOSE
BOX (900 CONFIG PW206A)
4. RH INTERCONNECT TEE FITTING VAPOR SHROUD 22. LOWER RH VAPOR SHROUD HOSE
BOX (900 CONFIG PW206A)
5. LH FUEL SHUTOFF VALVE VAPOR SHROUD BOX 23. LOWER LH FUEL SUPPLY HOSE ASSEMBLY
6. RH FUEL SHUTOFF VALVE VAPOR SHROUD BOX (900 CONFIG PW206A)
7. LH ENGINE FEED TUBE ASSEMBLY
24. LOWER RH FUEL SUPPLY HOSE ASSEMBLY
8. RH ENGINE FEED TUBE ASSEMBLY
(900 CONFIG PW206A)
9. LH INTERCONNECT TEE FITTING
25. BOLT
10. RH INTERCONNECT TEE FITTING
26. SHROUD BOX CAP
11. VAPOR SHROUD BOX CROSSFEED VALVE
27. TUBE FITTING CAP
(900 CONFIG PW206A)
12. UNION FITTING 28. STRAP, TIEDOWN, ELECTRICAL
13. PAN HEAD BOLT 29. GROMMET, MODIFIED
14. WASHER 30. JUMPER ASSEMBLY, ELECTRIC, BONDING, AND
15. NUT CURRENT RETURN
16. CUSHIONED SUPPORT CLAMP 31. CLAMP, LOOP TYPE, BONDING
17. SPACER 32. SCREW, HEX HEAD, RECESSED, FULL THREAD
18. WASHER 33. WASHER, FLAT
19. PAN HEAD BOLT 34. NUT, SELF LOCKING
Page 456
WL
WL 146.560
147.003
2.3 2.3
2.3 6.3
WL WL
147.000 146.560
2.30 2.30
25.50 25.50
10.7 13.3
WL WL
101.000 101.000
LOOKING FWD
9G28-040-1
Figure 420. Fuel Supply Tube Spacer Installation Location (Sheet 1 of 2)
Page 457
28-00-00 Revision 1
2.3 1.8
WL
101.000
3.2
LOOKING UP 2.3
LOOKING FORWARD
9G28-040-2
Figure 420. Fuel Supply Tube Spacer Installation Location (Sheet 2 of 2)

25. Inline Check Valve Alcohol, Isopropyl (C419)
(Ref. CSPSPM)
Item Nomenclature (3). Clean components with isopropyl
T20144 Manometer alcohol (C419).
C419 Alcohol, Isopropyl (4). Inspect components for contamination.
None allowed.
C103 Lubricant
(5). Inspect poppet for damage. None
allowed.
A. Disassembly (6). Inspect the surfaces that the O-ring
and static seal seat against for damage.
(Ref. Figure 421). None allowed.
B. Assembly
NOTE:
(1). Wipe clean the surfaces that the O-ring
You must have an overhaul kit to perform and static seal seat against on poppet
this procedure (Ref. CSP-900IPL-4). and end cap.
Use care when you remove the end cap Lubricant (C103)
from the housing, the poppet is spring
loaded.
Fuel, Aviation Turbine (C114)

(2). Lightly lubricate O-ring and static seal
with lubricant (C103).
NOTE: Install O-ring with color marking to
wards the poppet.
(3). Install new O-ring on poppet.
(1). Remove end cap (2) from housing (1).
(4). Install new static seal on end cap.
(2). Remove spring (3), poppet (4), O-ring (5). Apply a thin coat of lubricant (C103) to
(5), and static seal (6). Discard O-ring the housing threads and the area of the
and static seal. static seal seat.
Page 458
(6). Install spring into housing. (4). Check for air leakage. None allowed.
(7). Install poppet into housing.
(5). Connect the manometer (T2014-4)
(8). Install end cap into housing. between the pressure source and the
(9). Torque end cap 144 in-lb (16.27 Nwm). end cap (2).
C. Leak Check and Functional Test

Alcohol, Isopropyl (C419)
NOTE:
The procedure that follows makes sure
the check valve has one-way flow and no
leaks.
Use clean, regulated, low pressure, fil
tered, compressed air or nitrogen as a (6). Submerge check valve in isopropyl
pressure source. alcohol (C419) or suitable fluid.
(1). Connect housing (1) to the pressure
source. NOTE: Check for air flow from outlet port,
(2). Slowly apply pressure to 30 psig (207 while you apply pressure.
kPa).
Alcohol, Isopropyl (C419) (7). Slowly apply pressure to 0.29 psig (2
kPa) to get 8 inches of water mea
sured with the manometer (T2014-4) to
open the check valve.
(3). Submerge check valve in isopropyl (8). If the check valve did not open, discard.
alcohol (C419) or suitable fluid.
INLET PORT
6
5
OUTLET PORT
9g28-078
1. HOUSING 4. POPPET
2. END CAP 5. ORING
3. SPRING 6. STATIC SEAL
Figure 421. InLine Check Valve
Page 459
26. Jet Pump Alcohol, Isopropyl (C419)

A. Jet Pump Disassembly
(Ref. Figure 422)
Consumable Materials (3). Clean the ejector tube (2), nozzle

(Ref. CSPSPM) assembly (1), and orifice (3) with
Item Nomenclature isopropyl alcohol (C419).
(4). Inspect nylon thread locking pellet (4)
for condition and security. If nylon
thread locking pellet is unserviceable,
Fuel, Aviation Turbine (C114) replace jet pump.
B. Jet Pump Assembly
(Ref. Figure 422)

(1). Remove nozzle assembly (1) from
ejector tube (2).
NOTE: Make sure there is friction from the ny
lon thread locking pellet. If there is no fric
CAUTION tion, replace jet pump.
Do not use a tool with more than 0.050 in.
(1.27 mm) diameter. (1). Install the nozzle assembly into ejector
tube.
Make sure the tool is smooth before you
put it into the orifice.
(2). Torque nozzle assembly 180 in-lb
(2). Remove any obstruction from orifice (3). (20.34 Nwm)
3
9G28-080
1. NOZZLE ASSEMBLY 3. ORIFICE

2. EJECTOR TUBE 4. NYLON THREAD LOCKING PELLET
Figure 422. Jet Pump
Page 460
FUEL SYSTEM
INSPECTION / TEST
1. General Inspections for the Fuel Cell (a). Repair or replace components as
necessary.
A. Fuel Cell Inspection Fuselage Bottom
(1). Examine the gravity fill port filler neck: 06-00-00).
(a). Examine cap for missing or damaged (8). Do a check of the drain valve control
seal. cable for correct operation and freedom
of movement.
(b). Remove the filler cap.
(9). Examine the sump drain valves for
(c). Operate the fuel/defuel valve. leakage.
(d). Make sure the operation of fuel/de (a). No leakage of fuel from the sump
fuel valve is correct. drain valves is permitted for 5
minutes after the controls have been
(e). Examine lanyard for security. released.
(2). Examine the fuel vent fairings for (10). Examine the installation of the drain
damage. valve control cable clamps.
(a). Examine the fuel vent fairings for air (a). Repair or replace components as
flow blockage. necessary.
(b). Repair or replace as required. (11). Close Access Panel R185 (ref. Section
06-00-00).
(3). Remove Access Panel B178 (ref. Section
06-00-00). (12). Install Access Panel B178 (ref. Section
06-00-00).
(a). Examine the exterior of fuselage
beneath the fuel cell for indications of B. Fuel Cell Inspection Fuselage Cavity
fuel leakage.
NOTE: There is no definite minimum or maxi
(b). No leaks permitted. mum service life of the fuel cell. The best in
surance for trouble-free service is the prop
(c). Repair or replace components as er installation of the cell. Do periodic
required. inspections to find indications of fuel vent
system failure or leakage.
(4). Examine the installation of the fuel
booster pump. Aviation Turbine Fuel
(a). Repair or replace components as
necessary.
(5). Examine the fuel booster pump electri
Do the Fuel Cell Leak Check/Pressure
cal leads for condition and connectors
Test to find leaks in the fuel system. If the
for corrosion and installation.
pressure test does not find leakage, a
(a). Repair or replace components as visual inspection is not required.
necessary. Do a fuel cell cavity visual inspection
when floor panels are removed for other
(6). Examine the fuel quantity probe maintenance.
electrical connector for serviceable
condition, bent or broken pins, frayed or (1). Defuel the rotorcraft (ref. Section
broken wires. 12-00-00).
Page 601
(2). Remove the cabin seats, if applicable Aviation Turbine Fuel

(3). Remove the carpet, if applicable (ref.

Section 25-20-00).
NOTE:
The rotorcraft must be defueled Do a Fuel Cell Leak Check/Pressure Test
CAUTION before access panels AL155,
to find leaks in the fuel system. If the
AR155, AL165, AR165, AL230, and AR230 pressure test does not indicate leakage, a
are removed. Structural damage can occur if visual inspection is not necessary.
these panels are removed with fuel in the ro
torcraft. Do a fuel cell internal visual inspection
when floor panels are removed for other
maintenance.
(4). Remove access panels AL155, AR155,
AL165, AR165, AL230, and AR230 (ref. If allowable serviceability criteria is ex
Section 53-20-00). ceeded, contact MDHI Field Service De
partment for disposition.
(5). Examine the vapor shroud hoses for (1). Defuel the helicopter (ref. Section
cracks, deterioration, deformation, and 12-00-00).
security.
(2). Remove the cabin seats, if applicable
(a). No damage is permitted. (ref. Section 25-20-00).
(6). Examine the installation of the drain Section 25-20-00).
lines.
The rotorcraft must be defueled
CAUTION before access panels AL155,
necessary. AR155, AL165, AR165, AL230, and AR230
are removed. Structural damage can occur if
these panels are removed with fuel in the ro
(7). Inspect fuel filler neck for evidence of torcraft.
fuel leakage.
(a). Replace seals as necessary. A160, AL165, AR165, A170, A217,
AL230, and AR230 (ref. Section
(8). Install access panels AL155, AR155, 53-20-00).
AL165, AR165, AL230, and AR230 (ref. System Contamination
Section 53-20-00). CAUTION
(9). Install the carpet, if applicable (ref. (5). Examine the fuel cell access covers for
Section 25-20-00). evidence of fuel leakage and the
electrical bonding jumper for corrosion
(10). Install the cabin seats, if applicable and installation.
(ref. Section 25-20-00). (a). Repair or replace components as
necessary.
C. Fuel Cell Inspection Internal
(6). Remove the fuel cell access covers (ref.
NOTE: There is no definite minimum or maxi Section 28-00-00).
mum service life of the fuel cell. The best in (7). Examine the installation of the fuel cell
surance for trouble-free service is the prop baffles.
er installation of the cell. Do periodic
inspections to find indications of fuel vent (8). Make sure the flapper valves move
system failure or leakage. freely.
Page 602
(9). Examine the fuel cell longitudinal AL230, and AR230 (ref. Section
baffle for separation where the metal 53-20-00).
baffle connects to the rubber.
NOTE:
(a). No separation is permitted.
Use installation tool (T801) through hole
(10). Inspect the installation of the fuel cell in the cabin floor panel to lift the top of
frangible valves. the fuel cell for installation of screws to
support the fuel cell to floor panel. Install
(a). Repair or replace components as the vapor seal plug in the floor panel hole
necessary. (ref. Section 53-20-00).
(11). Inspect the fuel supply hoses for As an alternate method use high-grade
deterioration, collapsed or kinked steel all thread rods with large surface
hoses. flat washers and nuts. Insert threaded
rods through the cabin floor panel and
(a). No damage is permitted. threaded hole in the fuel access panel.
(12). Examine the the fuel supply hose Place large surface flat washers over the
clamps for installation and deteriora floor panel and threaded rods. With nuts
tion. installed on threaded rods, turn the nuts
down evenly until the fuel cell is located
(a). Repair or replace components as in the correct position to the cabin floor
necessary. panel.
(13). Examine the installation of the fuel (16). Do the Fuel Cell Leak Check/Pressure
quantity probes. Test (ref. Procedure 4.).
necessary. (17). Fuel the rotorcraft (ref. Section
12-00-00)
(14). Install the fuel cell access covers (ref.
Section 28-00-00, Removal/Installa (18). Install the carpet, if applicable (ref.
tion) Section 25-20-00).
(15). Install access panels AL155, AR155, (19). Install the cabin seats, if applicable
A160, AL165, AR165, A170, A217, (ref. Section 25-20-00).
Page 603
2. Inspections for the Fuel Vent System (b). Examine the hose connections for
cracks, cuts, tears, punctures, and
NOTE: There is no definite minimum or maxi collapsed hoses.
mum service life of the fuel vent system. The
best insurance for trouble-free service is the (c). Examine the installation of the
correct installation of the fuel vent system. clamps.
Do periodic inspections to find indications of (d). No damage is permitted.
fuel vent system failure or leakage.
(e). Repair or replace components as
A. Inspection of the Fuel Vent System necessary.
Aviation Turbine Fuel (6). Do an inspection of the forward and aft
standpipe vent tubes and flame
arrestors:
(a). Examine the fuel vent tubes for
cracks, dents, nicks, and corrosion.
NOTE:
(b). Examine the hose connections for
Do a Fuel Cell Leak Check/Pressure Test cracks, cuts, tears, punctures, and
to determine if there are leaks in the fuel collapsed hoses.
system. If the pressure test does not indi
cate leakage, a visual inspection is not (c). Examine the installation of the
necessary. clamps.
Do a visual inspection of fuel vent compo (d). No damage is permitted.
nents when floor panels are removed for
other maintenance. (e). Repair or replace components as
necessary.
(1). Remove the cabin seats, if applicable
(7). Examine the fuel vent float/rollover
valves for serviceable condition,
installation, leakage, and corrosion.
Section 25-20-00). (a). No damage is permitted.
The rotorcraft must be defueled (b). Repair or replace components as
CAUTION before access panels AL155, necessary.
AR155, AL165, AR165, AL230, and AR230
are removed. Structural damage can occur if (8). Inspect electrical bonding jumpers and
both of these panels are removed with fuel clamps for corrosion, damage, and
in the rotorcraft. installation.
(a). No damage is permitted.
A160, AL165, AR165, A217, AL230, (b). Repair or replace components as
and AR230 (ref. Section 53-20-00). necessary.
(4). Remove interior trim panels station 155 (9). Install access panels AL155, AR155,
left forward bulkhead as required (ref. A160, AL165, AR165, A217, AL230,
Section 25-10-00) and interior trim and AR230 (ref. Section 53-20-00).
panel aft bulkhead station 230.0 right
(10). Install the interior trim panels (ref.
side as required (ref. Section
Section 25-10-00).
25-20-00).
(11). Install the carpet, if applicable (ref.
(5). Do an inspection of the fuel vent tubes: Section 25-20-00).
(a). Examine the fuel vent tubes for (12). Install the cabin seats, if applicable
cracks, dents, nicks, and corrosion. (ref. Section 25-20-00).
Page 604
3. Inspections for the Fuel Supply System (e). Close Access Panel L210 or R210
A. Inspection of the Engine Fuel Feed Hose
B. Inspection of the Vapor Shroud Box,
Aviation Turbine Fuel Cover Assembly and Vapor Shroud Hose
(1). (900 CONFIG - PW206A) - Visually

examine the engine fuel feed hose.
(1). Open Access Door L262 (ref. Section
(a). Open Access Panel L210 or R210 (ref. 06-00-00).
Section 06-00-00). The rotorcraft must be defueled
CAUTION before both access panels AL165
(b). Inspect fuel feed hose fire sleeving for and AR165 are removed. Structural damage
deterioration and mechanical dam can occur if both of these panels are re
age. moved with fuel in the rotorcraft. Access
panel AL165 or AR165 can be removed indi
1). No damage is permitted.
vidually without a defuel of the rotorcraft.
(c). Inspect ``B nut for installation and (2). (Pre-TB900-003) Remove access
evidence of leakage. panels AL165, AR165, A235, AL250,
and AR250 (ref. Section 53-20-00).
1). Repair or replace components as
necessary. (Post-TB900-003) Remove access
panels L211 and R211 (ref. Section
(d). Close Access Panel L210 or R210 06-00-00).
(3). Examine the vapor shroud boxes and
(2). (902 CONFIG, 900 CONFIG PW206E covers for cracks and installation.
900 CONFIG PW207E) - Visually
examine the engine fuel feed hose. (a). No crack is permitted.
(a). Open Access Panel L210 or R210 (ref. (4). Examine the vapor shroud hoses for
Section 06-00-00). cracks, deterioration, deformation, and
installation.
(b). Inspect vapor shroud hose for cracks,
deterioration, deformation, and (a). No damage is permitted.
installation.
(5). Inspect the installation of the vapor
shroud hoses.
1). Repair or replace components as
necessary. (a). Repair or replace components as
necessary.
(c). Inspect FMU shroud box for cracks
and the installation of the latches. (6). (Pre-TB900-003) Install access panels
AL165, AR165, A235, AL250, and
1). Repair or replace components as AR250 (ref. Section 53-20-00).
necessary.
(Post-TB900-003) Install access
(d). Inspect the drain hose for cuts, panels L211 and R211 (ref. Section
chafes, and installation. 06-00-00).
1). Repair or replace components as (7). Close Access Door L262 (ref. Section
necessary. 06-00-00).
Page 605
TAPE OR PLUG
OPENINGS
TAPE OR PLUG
OPENINGS
28 INCH
(71.12 CM)
56 INCH
(142.24 CM)
TAPE OR
PLUG 0 INCH
OPENING (0.00 CM)
MANOMETER
ADAPTER PLUG REGULATED
OUTLET VALVE
TO PRESSURE
ADAPTER PLUG MANOMETER GAUGE
SUPPLY
AIR IN
T-FITTING SHUTOFF SHUTOFF

VALVE 2.5-PSIG VALVE 10-MICRON FILTER
REGULATOR FILTER
PREFERRED METHOD
9G28-043-2B
Figure 601. Fuel Cell Leak Check/Pressure Test Method 1
Page 606
4. Fuel Cell Leak Check/Pressure Tests (3). Make sure that all fuel lines have been
connected.
NOTE: Test method 1 or 2 are equally satisfac
tory. The operator can select which test to (4). Make sure there is no damage to the
do. fuel system components.
A. Fuel Cell Leak Check/Pressure Test The FUEL SHUTOFF valve
Method 1 CAUTION switch arms the fire extinguish
ing system. Make sure BOTTLE DIS
NOTE: It will be necessary to partially remove CHARGE switch is set in the OFF position.
the cabin floor if you do Method 1.
(5). Make sure that the LH and RH engine
(Ref. Figure 601)
fuel shut-off valves are in the
Aviation Turbine Fuel CLOSED position on the FUEL
SYSTEM control panel.
(6). Make sure the fuel filler cap is tight.
(7). Plug, cap, or tape shut the aft fuel vent
system outlet (vent fairing).
(Ref. CSPSPM) (8). Remove Access Panel AL230 (ref.
Item Nomenclature Section 53-20-00).
C702 Lockwire
(9). Remove AN814-8DL plug from the
C809 Leak Detector, Liquid auxiliary fuel port on the left aft fuel cell
vent fitting.
Special Tools (10). Install adapter (T2014-5).

(Ref. CSPSPM)
(11). Use air pressure regulator (T2014-6),
Item Nomenclature
pressure gauge (T2014-2), and shut-off
T2014 Pressure Test Kit valve (T2014-3).
T20141 Filter, 10 Micron
T20142 Pressure Gauge, 0.5 Increment (12). Connect the air supply hose and
U-tube manometer (T2014-4) hose to
T20143 ShutOff Valve
adapter (T2014-5).
T20144 Manometer
T20145 Adapter Make sure access panels A160,
CAUTION A170, and A217 are installed
T20146 Regulator, Air Pressure
before you apply air pressure.
(1). Clean all grease, oil, and foreign (13). If new fuel cell is installed, slowly apply
material from the interior and exterior 2.0 psig (13.8 kPa) clean filtered
surfaces of components before you begin regulated air pressure to get 56 inch
this test. (142.24 cm) of water as measured on
manometer (T2014-4) to the port.
The helicopter must be drained
CAUTION of all fuel before a functional (a). Hold for 10 minutes as a precaution
leak test can be done. ary measure.
NOTE: When this test is done to satisfy the in NOTE: This will let air trapped between the fuel
spection requirements, it is not necessary to cell and the helicopter structure to escape and
completely defuel the helicopter. The fuel also let the cell adjust to the contour of the
level cannot be more than 600 lb (272 kg). cell cavity.
(2). Defuel and drain fuel cell sump of all (b). Release the air pressure slowly and
fuel (ref. Section 12-00-00). repeat if necessary.
Page 607
(14). Slowly apply 2.0 psig (13.8 kPa) of (e). Remove the interior trim panels of
clean, filtered, regulated air pressure to Station 155 left forward bulkhead as
get 56 inch (142.24 cm) of water to required (ref. Section 25-10-00).
the fuel cell as measured on manometer
(T2014-4). (f). Remove the interior trim panel aft of
the bulkhead Station 230.0 right side
(15). Make sure the air pressure inside does as required (ref. Section 25-20-00).
not fall more than 0.125 psig (0.86
kPa) or 3.5 inch (8.89 cm) of water (g). Do a test of the fuel vent connections.
after 15 minutes as measured with
manometer (T2014-4). (h). Remove access panels AL138 and
AL129 (ref. Section 53-20-00).
(16). If the test is successful, slowly release
the air pressure from the fuel cell. (i). Do a test of the fuel vent connections.
(17). Remove adapter from auxiliary fuel (j). Remove access panels AL155,
port. AR155, AL230, and AR230 (ref.
Section 53-20-00).
(18). Install AN814-8DL plug.
(k). Do a test of float/ rollover valves and
(a). Torque plug. vent connections.
(b). Safety plug with lockwire (C702). NOTE: If an air-conditioning condenser exit
(19). Remove plug, cap, or tape from the screen is installed, use for access instead of
forward and aft fuel vent system outlet baggage compartment floor removal. Leave
(vent fairing). one screw loosely attached to prevent screen
from falling inside.
(20). Install removed panels (ref. Section
53-20-00). (l). Remove Access Panel A235 (ref.
Section 53-20-00).
Do not attempt to remove
WARNING access panels with air pres (m). Do a test of the vent connections and
sure applied. This can cause serious in vapor shroud system and fuel supply
jury to personnel and damage to the fu system, if necessary.
selage structure.
(n). Do the vapor shroud press test.
(21). If leakage is more than the permitted
amount, apply liquid leak detector 1). If necessary, correct leaks in vapor
(C809) to areas you think have leaks. shroud system.
NOTE: If helicopter is partially fueled, inspect 2). Put caps on the vapor shroud
area for fuel leakage instead of air bubbles. system.
Follow this sequence to find leaks in the
most accessible areas first. Do a test of each 3). Do a test of the fuel system again.
area one after the other to find the leak.
4). If there are no leaks, then the
(a). Open Access Panel R185 (ref. Section problem is in fuel supply system.
06-00-00).
5). Take the caps off the vapor shroud
(b). Do a test of the fuel drain valves. system.
(c). Remove Access Panel B178 (ref. 6). Make sure of the leakage.
Section 06-00-00).
(o). Remove Access Panel AR165 (ref.
(d). Do a test of the fuel pumps, fuel Section 53-20-00).
gauging probes, and fuel drain
valves. (p). Do a test of the filler neck area.
Page 608
The rotorcraft must be defueled (b). Do the fuel cell leak check/pressure
CAUTION before access panels A160, test again.
A170, and/or A217 or both AL165 and
AR165 are removed. Structural damage can (25). If the test is successful, slowly release
occur if one of these panels is removed with the air pressure from the fuel cell.
fuel in the rotorcraft.
(26). Remove adapter from auxiliary fuel
(22). Remove access panels A160, A170, and port.
A217 (ref. Section 53-20-00).
(23). Leakage must be at fuel cell covers or (27). Install AN814-8DL plug.
fuel cell itself.
(a). Torque plug.
Make sure access panels A160,
CAUTION A170, and A217 are installed
(b). Safety plug with lockwire (C702).
before you apply air pressure.
(24). Examine all fittings and components (28). Remove plug, cap, or tape from the
for leaks. forward and aft fuel vent system outlet
(vent fairing).
(a). Tighten loose fittings, replace dam
aged seals or components as neces (29). Install removed panels (ref. Section
sary. 53-20-00).
Page 609
TAPE OR PLUG
OPENINGS
28 INCH
(71.12 CM)
56 INCH
(142.24 CM)
0 INCH
(0.00 CM)
MANOMETER
REGULATED
OUTLET VALVE PRESSURE
GAUGE
TO
MANOMETER
SUPPLY
AIR IN
T-FITTING SHUTOFF SHUTOFF

VALVE VALVE
2.5-PSIG 10-MICRON FILTER
REGULATOR FILTER
ALTERNATE METHOD 9G28-043-1B
Figure 602. Fuel Cell Leak Check/Pressure Test Method 2
Page 610
B. Fuel Cell Leak Check/Pressure Test The FUEL SHUTOFF valve

Method 2 CAUTION switch arms the fire-extin
guishing system. Make sure BOTTLE DIS
NOTE: It is not necessary to remove the cabin CHARGE switch is OFF.
floor if you do Method 2.
(5). Make sure that the LH and RH engine
(Ref. Figure 602) fuel shut-off valves are in CLOSED
position on the FUEL SYSTEM panel.
(6). Make sure the fuel filler cap is tight.
(7). Plug, cap, or tape shut the aft fuel vent

system outlet (vent fairing).
Consumable Materials Make sure access panels A160,

(Ref. CSPSPM) CAUTION A170, and A217 are installed
Item Nomenclature (ref. Section 53-20-00) before you apply air
C702 Lockwire pressure.
C809 Leak Detector, Liquid (8). Connect the air supply and U-tube
manometer (T2014-4) hose to the
forward fuel vent system outlet.
Special Tools
(Ref. CSPSPM) (a). Attach the air supply and U-tube
Item Nomenclature hoses to the forward fuel vent system
fairing with tape.
T2014 Pressure Test Kit
T20141 Filter, 10 Micron (9). Use air pressure regulator (T2014-6),
T20142 Pressure Gauge, 0.5 Increment pressure gauge (T2014-2), and shut-off
T20143 ShutOff Valve valve (T2014-3).
T20144 Manometer
(10). Slowly apply 2.0 psig (13.8 kPa) of
T20146 Regulator, Air Pressure clean, filtered, regulated air pressure to
get 56 inch (142.24 cm) of water to
(1). Clean all grease, oil, and foreign the fuel cell as measured on manometer
material from the interior and exterior (T2014-4).
surfaces of components before you begin
(11). Turn air pressure regulator (T2014-6)
this test.
OFF.
The rotorcraft must be drained
CAUTION of all fuel before a functional (12). Make sure the air pressure inside does
leak test can be done. not fall more than 0.125 psig (0.86
kPa) or 3.5 inch (8.89 cm) of water
(2). Defuel and drain fuel cell sump of all after 15 minutes as measured with
fuel (ref. Section 12-00-00). manometer (T2014-4).
NOTE: When this test is done to satisfy the in (13). If test is successful, slowly release air
spection requirements, it is not necessary to pressure from fuel cell.
completely defuel the rotorcraft. The fuel
level cannot be more than 600 lb (272 kg). (14). Disconnect test equipment.
(3). Make sure all the fuel lines are correct (15). Remove plug, cap, or tape from the aft
ly connected. fuel vent system outlet (vent fairing).
(4). Make sure there is no damage to the (16). Install removed panels (ref Section
fuel system components. 53-20-00).
Page 611
Do not attempt to remove (m). Do a test of the vent connections and

WARNING access panels with air pres vapor shroud system and fuel supply
sure applied. This can cause serious in system, if necessary.
jury to personnel and damage to the fu
selage structure. (n). Do the vapor shroud press test.
1). If necessary, correct leaks in vapor
(17). If leakage is more than the permitted
shroud system.
amount, apply liquid leak detector
(C809) to areas you think have leaks. 2). Put caps on the vapor shroud
system.
NOTE: If the rotorcraft is partially fueled, in
spect area for fuel leakage instead of air 3). Do a test of the fuel system again.
bubbles. Follow this sequence to find leaks
in the most accessible areas first. Do a test 4). If there are no leaks, then the
of each area one after the other to find the problem is in fuel supply system.
leak. 5). Take the caps off the vapor shroud
(a). Open Access Panel R185 (ref. Section system.
06-00-00). 6). Make sure of the leakage.
(b). Do a test of the fuel drain valves. (o). Remove Access Panel AR165 (ref.
Section 53-20-00).
(c). Remove Access Panel B178 (ref.
Section 06-00-00). (p). Do a test of the filler neck area.
(d). Do a test of the fuel pumps, fuel Do not attempt to remove
gauging probes, and fuel drain WARNING access panels with air pres
valves. sure applied. This can cause serious in
jury to personnel and damage to the fu
(e). Remove the interior trim panels of selage structure.
Station 155 left forward bulkhead as
required (ref. Section 25-10-00). (18). Slowly release air pressure from fuel
cell.
(f). Remove the interior trim panel aft of
The rotorcraft must be defueled
the bulkhead Station 230.0 right side CAUTION before access panels A160,
as required (ref. Section 25-20-00).
A170, and/or A217 or both AL165 and
(g). Do a test of the fuel vent connections. AR165 are removed. Structural damage can
occur if one of these panels is removed with
(h). Remove access panels AL138 and fuel in the rotorcraft.
AL129 (ref. Section 53-20-00).
(19). Remove access panels A160, A170, and
(i). Do a test of the fuel vent connections. A217 (ref. Section 53-20-00).
(j). Remove access panels AL155, (20). Leakage must be at fuel cell covers or
AR155, AL230, and AR230 (ref. fuel cell itself.
Section 53-20-00). (21). Examine all fittings and components
(k). Do a test of float/ rollover valves and for leaks.
vent connections. (a). Tighten loose fittings and replace
damaged seals or components as
(l). Remove Access Panel A235 (ref.
necessary.
Section 53-20-00).
(b). Do the fuel cell leak check/pressure
NOTE: If an air-conditioning condenser exit test again.
screen is installed, use the exit screen for ac
cess instead of Access Panel A235. Leave (22). If the test is successful, slowly release
one screw loosely installed. the air pressure from the fuel cell.
Page 612
(23). Disconnect the test equipment. fairing).

(24). Remove the plug, cap, or tape from the (25). Install access panels A160, A170, A217,
aft fuel vent system outlet (vent and AR165 (ref Section 53-20-00).
Page 613
CAP, PLUG OR
CLAMP SHUT
CAP, PLUG OR
CLAMP SHUT
CAP, PLUG OR
CLAMP SHUT
APPLY AIR
PRESSURE
CAP, PLUG OR
CLAMP SHUT
9G28-035-1
Figure 603. Fuel Supply Vapor Shroud Leak Check / Pressure Test (900 CONFIG) (Sheet 1 of 2)
Page 614
2
1
1 REF
4 3
5
VIEW LOOKING FORWARD AT FS 230.5

MODIFIED CROSSFEED INSTALLATION
900 CONFIG
LH SHOWN RH OPPOSITE
9P28-035-2
1. CROSSFEED VALVE 4. STRAP, TIEDOWN, ELECTRICAL

2. LH CROSSFEED HOSE ASSEMBLY 5. VAPOR SHROUD
3. GROMMET
Figure 603. Fuel Supply Vapor Shroud Leak Check / Pressure Test (900 CONFIG) (Sheet 2 of 2)
5. Fuel Supply Vapor Shroud Leak The rotorcraft must be defueled
Check/Pressure Test CAUTION before both access panels AL165
and AR165 are removed. Structural damage
A. Fuel Supply Vapor Shroud Leak can occur if both of these panels are re
Check/Pressure Test (900 CONFIG) moved with fuel in the rotorcraft. Panel
AL165 or AR165 can be removed individual
(Ref. Figure 603) ly without a defuel of the rotorcraft.
(1). (Pre-TB900-003) Remove access

Consumable Materials panels AL165, AR165, A235, AL250,
(Ref. CSPSPM) and AR250 (ref. Section 53-20-00).
Item Nomenclature
(Post-TB900-003) Remove access
C702 Lockwire panels L211 and R211 (ref. Section
C809 Leak Detector, Liquid 06-00-00.)
(2). Plug or clamp shut the left and right

fuel cell frangible valve outlet shroud
Special Tools drain hoses (0.250 ID rubber hose).
(Ref. CSPSPM)
Item Nomenclature (3). Disconnect the left and right vapor
T20144 Manometer shroud drain hoses (0.250 in ID rubber
hose) from the engine drain hose tee
T20145 Adapter
fittings.
(4). Plug or clamp shut the drain hoses.
Page 615
(5). Apply and maintain a constant 2.0 psig

(13.8 kPa) or 56 inch (142 cm) of Special Tools
water regulated air pressure to the (Ref. CSPSPM)
crossfeed valve shroud drain hose Item Nomenclature
(0.250 inch ID rubber hose). T20144 Manometer
T20145 Adapter
(a). With the air pressure applied, the T20146 Regulator, Air Pressure
manometer (T2014-4) must indicate
28 to 56 inch (71 to 142 cm) of
water. NOTE: This functional test is typical for LH or
RH Fuel Vapor Shroud System. Repeat test
for the opposite side fuel vapor shroud sys
(6). With air pressure applied, do a check tem.
for external leakage of the shrouds and
drains with liquid leak detector (C809). The rotorcraft must be defueled
CAUTION before both access panels AL165
(a). Repair or replace as necessary and can occur if both of these panels are re
retest. moved with fuel in the rotorcraft. Panel
AL165 or AR165 can be removed individual
(7). If test is successful, remove air source ly without a defuel of the rotorcraft.
from crossfeed valve drain hose.
(1). (Pre-TB900-003) Remove access
panels AL165, AR165, A235, AL250,
(8). Unplug and reconnect left and right and AR250 (ref. Section 53-20-00).
vapor shroud drain hoses to the engine
drain hose tee fittings. (Post-TB900-003) Remove access
panels L211 and R211 (ref. Section
06-00-00).
(9). Unplug the left and right fuel cell
frangible valve outlet shroud drain (2). Disconnect the left or right vapor
hoses. shroud drain hose (0.250 inch (6.35
mm) ID rubber hose) from the engine
(10). (Pre-TB900-003) Install access panels drain hose tee fitting.
AL165, AR165, A235, AL250, and (3). Plug or clamp shut the drain hose.
AR250 (ref. Section 53-20-00).
(4). Apply and maintain a constant 2.0 psig
(13.8 kPa) or 56 inch (142 cm) of
(Post-TB900-003) Install access water regulated air pressure to the left
panels L211 and R211 (ref. Section or right fuel cell frangible valve outlet
06-00-00). shroud drain hose (0.250 inch (6.35
mm) ID rubber hose).
B. Fuel Supply Vapor Shroud Leak
Check/Pressure Test (900 CONFIG) With (a). With the air pressure applied, the
Supplemental Fuel System manometer (T2014-4) must indicate
28 to 56 inch (71 to 142 cm) of
water.
(Ref. Figure 603)
(5). With air pressure applied, do a check
for external leakage of the shrouds and
Consumable Materials drains with liquid leak detector (C809).
(Ref. CSPSPM)
(a). Repair or replace as necessary and
Item Nomenclature
retest.
C702 Lockwire
(6). If test is successful, remove air source
C809 Leak Detector, Liquid from fuel cell frangible valve outlet
shroud drain hose.
Page 616
(7). (Pre-TB900-003) Install access panels (Post-TB900-003) Install access

AL165, AR165, A235, AL250, and panels L211 and R211 (ref. Section
AR250 (ref. Section 53-20-00). 06-00-00.)
Page 617
APPLY AIR
PRESSURE
CAP, PLUG OR
CLAMP SHUT
CAP, PLUG OR
CLAMP SHUT
APPLY AIR
PRESSURE
AIRFRAME FUEL FILTER OPTION SHOWN
CAP, PLUG OR
CLAMP SHUT
APPLY AIR
PRESSURE
CAP, PLUG OR
CLAMP SHUT
APPLY AIR
PRESSURE
9G28-054A
Figure 604. Fuel Supply Vapor Shroud Leak Check/Pressure Test (902 CONFIG)
Page 618
C. Fuel Supply Vapor Shroud Leak (5). Disconnect the left or right vapor
Check/Pressure Test (902 CONFIG) shroud drain hose (0.250 in ID rubber
hose) from the engine drain hose tee
(Ref. Figure 604) fitting.
Consumable Materials (6). Plug or clamp shut the drain hose.

(Ref. CSPSPM)
Item Nomenclature
(7). Apply and maintain a constant
0.2 +0.7 psig (1.38 kPa) or 4.0 to 8.0
C702 Lockwire inch (10.2 to 20.3 cm) of water
C809 Leak Detector, Liquid regulated air pressure to the left or
right fuel cell frangible valve outlet
shroud drain hose (0.250 inch ID
Special Tools rubber hose).
(Ref. CSPSPM)
Item Nomenclature (a). With the air pressure applied, the
manometer (T2014-4) must indicate
T20144 Manometer 4.0 to 8.0 inch (10.2 to 20.3 cm) of
T20145 Adapter water.
(8). With air pressure applied, check for any
external leakage of the shrouds and
NOTE: This functional test is typical for LH or drains with liquid leak detector (C809).
RH Fuel Vapor Shroud System. Repeat test
for the opposite side fuel vapor shroud sys (a). Repair or replace as necessary and
tem. retest.
(1). Open access panels L210 or R210 (ref. (9). If test is successful, remove air source
Section 06-00-00). from fuel cell frangible valve outlet
(2). Remove and discard lockwire and shroud drain hose.
disconnect vapor shroud duct (1.50 ID (10). Unplug and reconnect left or right
hose) from top of FMU vapor shroud vapor shroud drain hose to the engine
box. drain hose tee fitting.
(3). Plug vapor shroud box opening.
(11). (Pre-TB900-003) Install access panels
The rotorcraft must be defueled AL165, AR165, A235, AL250, and
CAUTION before both access panels AL165 AR250 (ref. Section 53-20-00).
can occur if both of these panels are re (Post-TB900-003) Install access
moved with fuel in the rotorcraft. Panel panels L211 and R211 (ref. Section
AL165 or AR165 can be removed individual 06-00-00).
ly without a defuel of the rotorcraft.
(12). Connect vapor shroud duct to top of
(4). (Pre-TB900-003) Remove access FMU vapor shroud box.
panels AL165, AR165, A235, AL250,
and AR250 (ref. Section 53-20-00). (13). Safety vapor shroud duct with lockwire
(C702).
(Post-TB900-003) Remove access
panels L211 and R211 (ref. Section (14). Close access panels L210 or R210 (ref.
06-00-00). Section 06-00-00).
Page 619
6. Operational Tests for the Fuel System 2). Make sure the CROSSFEED
switch (900 CONFIG) is set to
A. Operation Test of the Fuel System OFF.
(Ref. Figure 605, Figure 606, and Figure 607) 3). Make sure the L BOOST switch is
set to OFF.
(1). Check fuel quantity probe operation.
4). Make sure the R BOOST switch is
(a). On the ELECTRICAL MASTER set to OFF.
panel, set the POWER switch to
(b). On the IIDS display observe:
BAT/EXT.
1). Right engine fuel pressure seg
(b). On the IIDS display observe: ments (white) are not illuminated.
1). FUEL quantity segments (green) 2). Left engine fuel pressure segments
are illuminated with fuel quantity (white) are not illuminated.
greater than 250 lbs.
3). Right engine fuel shutoff valve
2). FUEL quantity LB digital display segments (yellow) are illuminated.
read out of fuel quantity is illumi
4). Left engine fuel shutoff valve
nated and approximately matches
segments (yellow) are illuminated.
FUEL quantity segments.
5). Right engine low fuel pressure
3). FUEL low level caution segments caution segments (yellow) are not
(yellow) illuminated indicates illuminated.
approximately 150-300 lbs fuel
remaining. 6). Left engine low fuel pressure
caution segments (yellow) are not
4). FUEL low level warning segments illuminated.
and tick marks (red) illuminated
indicates approximately 150 lbs 7). Crossfeed valve segment (white)
fuel or less remaining. not illuminated (900 CONFIG).
(c). On the FUEL SYSTEM panel:
Do not operate booster pumps
CAUTION dry. A minimum of 141 to 151 1). Set the RIGHT guarded FUEL
lb. (22 to 24 US gal / 82.0 to 88.0 L) of fuel SHUTOFF switch to ON.
must be in fuel cell.
2). Set the LEFT guarded FUEL
(2). Do a check of left and right booster SHUTOFF switch to ON.
pump operation, left and right fuel (d). On the IIDS display observe:
shutoff valve operation, crossfeed valve
operation (900 CONFIG), and light 1). Right engine low fuel pressure
segment integrities on IIDS panel: caution alternating offset segments
(white-yellow) are illuminated.
The FUEL SHUTOFF valve
CAUTION switch arms the fire extinguish 2). Left engine low fuel pressure
ing system. Make sure BOTTLE DIS caution alternating offset segments
CHARGE switch is set in OFF position. (white-yellow) are illuminated.
(e). On the FUEL SYSTEM panel, set
NOTE: If fire extinguishing system is NOT the L BOOST switch to ON.
installed, disregard caution relating to fire
bottle discharge in operational test. (f). On IIDS display observe that the left
engine fuel pressure segments
(a). On the FUEL SYSTEM panel: (white) are illuminated.
1). Make sure the FUEL SHUTOFF, (g). (900 CONFIG) - On the FUEL
BOTTLE DISCHARGE switch is SYSTEM panel, set CROSSFEED
set to OFF. switch to ON.
Page 620
(h). (900 CONFIG) - On the IIDS (k). On the FUEL SYSTEM panel:
display observe:
1). (900 CONFIG) - Set the CROSS
1). Right engine fuel pressure seg FEED switch to OFF..
ments (white) are illuminated.
2). Set the L BOOST switch to ON.
2). Crossfeed valve segment (white) is
illuminated.
(l). On the IIDS display observe:
3). Left engine fuel pressure segments
(white) are illuminated. 1). Left engine fuel pressure segments
(white) are illuminated.
(i). On FUEL SYSTEM panel:
2). (900 CONFIG) - Crossfeed valve
1). Set the L BOOST switch to OFF. segment (white) is not illuminated.
2). Set the R BOOST switch to ON. 3). Right engine fuel pressure seg
ments (white) are illuminated.
(j). On the IIDS display observe:
(m). On the FUEL SYSTEM panel:
1). Left engine fuel pressure segments
(white) are illuminated.
1). Set the L BOOST switch to OFF..
2). (900 CONFIG) - Crossfeed valve
segment (white) is illuminated. 2). Set the R BOOST switch to OFF..
3). Right engine fuel pressure seg (3). On the ELECTRICAL MASTER
ments (white) are illuminated. panel, set the POWER switch to OFF.
900 CONFIG 902 CONFIG 9G28-046A
Figure 605. Fuel System Panel / Electrical Master Panel
Page 621
FUEL FILTER FUEL FILTER

IMPENDING (NOTE) IMPENDING BY-PASS
BY-PASS CAUTION CROSSFEED VALVE CAUTION
FIRE FIRE FIRE CAB HEAT (YELLOW) POSITION (WHITE)
CHIPS CHIPS CHIPS BAT HOT
BAT WRM
C %PSI C %PSI C %PSI ROTOR
BRAKE FUEL SHUTOFF
CABIN VALVE (YELLOW) FUEL SHUTOFF
DOOR (NOTE ) VALVE (YELLOW)
FUEL (NOTE )

BAGGAGE FUEL
%LOAD %LOAD DOOR

GEN GEN 1 HYD 2
FUEL QUANTITY
SEGMENTS
NG NG
IIDS

LOW FUEL CAUTION

SEGMENT
LB C LOW FUEL (YELLOW)
WARNING
OAT TICK (RED)
LOW FUEL WARNING
SEGMENT (RED)
YELLOW
WHITE

RED
GREEN
LB
FUEL QUANTITY DIGITAL
DISPLAY (WHITE)
A. NORMAL FUEL PRESSURE ON IIDS SECONDARY DISPLAY PANEL

D. INDICATES LOW FUEL PRESSURE ON BOTH FUEL BOOSTER PUMPS
OR BOTH BOOSTER PUMPS IN OFF POSITION
B. NORMAL FUEL PRESSURE WITH CROSSFEED VALVE OPEN (NOTE)

E. LOW FUEL PRESSURE LEFT BOOSTER PUMP WITH NORMAL
FUEL PRESSURE ON RIGHT BOOSTER PUMP
C. NORMAL FUEL FLOW WITH IMPENDING ENGINE FUEL FILTERS BY-PASS
F. INDICATES BOTH FUEL SHUTOFF VALVES IN CLOSED POSITION (NOTE )

NOTE: THE LIGHT SEGMENT BAR(S) WILL FLASH ON THE IIDS PANEL WHEN THE VALVE
IS IN TRANSIT BETWEEN THE OPEN AND CLOSED POSITION. 9G28-039A
Figure 606. 900 CONFIG Fuel System IIDS Secondary Panel Display
Page 622
FUEL FILTER FUEL FILTER

IMPENDING IMPENDING BY-PASS
BY-PASS CAUTION CAUTION
FIRE FIRE FIRE CAB HEAT (YELLOW)
CHIPS CHIPS CHIPS BAT HOT
BAT WRM
C %PSI C %PSI C %PSI ROTOR
BRAKE FUEL SHUTOFF
CABIN VALVE (YELLOW) FUEL SHUTOFF
DOOR VALVE (YELLOW)

(NOTE )
FUEL (NOTE )
BAGGAGE FUEL
%LOAD %LOAD DOOR

GEN GEN 1 HYD 2
FUEL QUANTITY
SEGMENTS

IIDS LOW FUEL CAUTION

SEGMENT
NG NG (YELLOW)
LB
OAT
C LEFT LOW FUEL
WARNING TICK (RED) RIGHT LOW FUEL
WARNING TICK (RED)
LOW FUEL WARNING
SEGMENT (RED)
YELLOW
WHITE RED
GREEN
LB
FUEL QUANTITY DIGITAL
DISPLAY (WHITE)
A. NORMAL FUEL PRESSURE WITH CROSSFEED VALVE SHOWN IN

NORMAL CLOSED POSITION ON IIDS SECONDARY DISPLAY PANEL C. INDICATES LOW FUEL PRESSURE ON BOTH FUEL BOOSTER PUMPS
OR BOTH BOOSTER PUMPS IN OFF POSITION
B. NORMAL FUEL FLOW WITH IMPENDING ENGINE FUEL FILTERS BY-PASS D. LOW FUEL PRESSURE LEFT BOOSTER PUMP WITH NORMAL
FUEL PRESSURE ON RIGHT BOOSTER PUMP
E. INDICATES BOTH FUEL SHUTOFF VALVES IN CLOSED POSITION (NOTE )
NOTE: THE LIGHT SEGMENT BAR(S) WILL FLASH ON THE IIDS PANEL WHEN THE VALVE
IS IN TRANSIT BETWEEN THE OPEN AND CLOSED POSITION. 9G28-058
Figure 607. 902 CONFIG Fuel System IIDS Secondary Panel Display
Page 623
7. Operational Tests for the Fuel Distribution (b). Set the L BOOST switch to ON.
System
(c). The booster pump must operate
(Ref. Figure 605, Figure 606, and Figure 607) audibly.
A. Operational Test of the Fuel Booster (5). Make sure that the left engine low fuel
Pump pressure (yellow) segments on the IIDS
display are not illuminated.
NOTE:
NOTE: A row of white segments indicate nor
This test is typical for the LH and RH fuel mal fuel pressure and alternating white and
booster pump. Instructions are written yellow offset segments indicate low fuel
for LH fuel booster pump. pressure.
If the fire-extinguishing system is not
installed, disregard caution relating to (6). On the FUEL SYSTEM panel:
bottle discharge in operational test. (a). Set the L BOOST switch to OFF.
Do not operate booster pump (b). Make sure the left engine low fuel
CAUTION dry. A minimum of 141 to 151 lb pressure (yellow) segments on the
(22 to 24 US gal / 83.0 to 90.0 L) of fuel IIDS display are illuminated.
must be in fuel cell.
(7). (900 CONFIG) - Set the CROSS
(1). On the ELECTRICAL MASTER FEED switch to ON and set the R
panel, set the POWER switch to BOOST switch to ON.
BAT/EXT.
(a). The booster pump must operate
The FUEL SHUTOFF valve audibly.
CAUTION switch arms the fire-extin
guishing system. Make sure the BOTTLE (b). Make sure the left and right engine
DISCHARGE switch is in the OFF posi low fuel pressure (yellow) segments
tion. on the IIDS display are not illumi
nated.
(2). On the FUEL SYSTEM panel, set the
BOTTLE DISCHARGE switch to (8). (900 CONFIG) - On the FUEL
OFF. SYSTEM panel:
(3). On the FUEL SYSTEM panel: (a). Set the R BOOST switch and the
CROSS FEED switch to OFF.
(a). Make sure the LEFT and RIGHT
(b). Make sure the left and right engine
FUEL SHUTOFF switches are both
low fuel pressure (yellow) segments
OFF.
on the IIDS display are illuminated.
(b). Make sure the L BOOST and R (9). Set the LEFT guarded FUEL SHUT
BOOST switches are OFF. OFF switch to LEFT OFF.
(c). (900 CONFIG) - Make sure the (10). On ELECTRICAL MASTER panel,
CROSS FEED switch is OFF. set POWER switch to OFF.
CAUTION
Make sure that throttle twist B. Operational Test of the Fuel ShutOff
grips are in NORMAL position Valve
and the ENGINE CONTROL switches are
in the OFF position to prevent accidental NOTE:
engine start or fire. This test is typical for LH and RH shut-
off valve.
(4). On the FUEL SYSTEM panel:
If the fire-extinguishing system is not
(a). Set the LEFT guarded FUEL installed, disregard caution relating to
SHUTOFF switch to ON. bottle discharge in operational test.
Page 624
(1). On ELECTRICAL MASTER panel, (4). On the ELECTRICAL MASTER

set POWER switch to BAT/EXT. panel, set the POWER switch to OFF.
The FUEL SHUTOFF valve C. Operational Test of the Crossfeed

CAUTION switch arms the fire extinguish ShutOff Valve (900 CONFIG)
ing system. Make sure BOTTLE DIS (Ref. Figure 605 and Figure 606)
CHARGE switch is set in OFF position.
(1). On the FUEL SYSTEM panel, set the
(2). Set guarded FUEL SHUTOFF valves CROSS FEED switch to ON.
to OFF position.
(a). The valve must operate audibly.
(a). The yellow segment bars will flash on
the IIDS panel when the valve is in (b). The white segment bar will flash on
transit between the open and closed the IIDS panel when the valve is in
position and remain on after reach transit between the open and closed
ing the closed position. position and remain on after reach
ing the full open position.
(3). Return FUEL SHUTOFF valve on the
(2). Set the CROSS FEED switch on
FUEL SYSTEM control panel to ON FUEL SYSTEM panel to OFF.
position.
(a). The white segment bar will flash on
(a). The valve must operate audibly. the IIDS panel when the valve is in
transit between the open and closed
(b). The yellow segment bars will flash on position and remain off after reach
the IIDS panel when the valve is in ing the full closed position.
transit between the open and closed
position and remain off after reach (3). On the ELECTRICAL MASTER
ing the open position. panel, set the POWER switch to OFF.
Page 625
8. Functional Tests for the Fuel Quantity (6). Use helicopter jack (T202) to jack
Indication System rotorcraft evenly to get a 5 nose down
simulated flight attitude on the
A. Functional Test of the Fuel Quantity inclinometer scale placed longitudinally
Indication System on the cabin floor, and level laterally
NOTE: This procedure calibrates the fuel quan across the cabin floor.
tity system when the fuel cell or fuel probes
have been replaced. (7). Stabilize the rotorcraft with wooden
blocks under landing gear skid tubes as
(Ref. Figure 605, Figure 606, and Figure 607) required.
Aviation Turbine Fuel (8). For rotorcraft that are defueled, add to
the fuel cell 2.60 US gal (9.84 L) as
measured from a calibrated fuel truck
metering system.
NOTE: The difference between a completely

Special Tools dry fuel cell and a defueled fuel cell is 0.23
(Ref. CSPSPM) US gal (0.87 L) of trapped fuel in the cell
Item Nomenclature which cannot be recovered.
T201 Jack Pad Kit
T202 Helicopter Jack (9). For rotorcraft which are completely dry
T203 Inclinometer
of fuel, including the sump area, add to
the fuel cell 2.83 US gal (10.71 L) as
T807 Thermometer
measured from a calibrated fuel truck
T808 Scale metering system.
Make sure the rotorcraft is on (10). Alternate Method:

CAUTION on stable and level ground be
(a). Record empty weight of a suitable
fore you do the fuel quantity test.
container.
(1). Attach the rotorcraft to an approved
electrical ground (ref. Section (b). Calculate the approximate weight of
10-10-00). fuel:
(2). Remove the filler cap and secure the 1). Find the fuel density for one gallon
lanyard in the slot provided in the filler based on type of fuel and the
cap adapter. temperature of the fuel measured
with a thermometer (T807) (ref.
(3). Defuel and drain fuel cell sump of all Figure 608).
fuel with aircraft at a normal ground
attitude (ref. Section 12-00-00). 2). Multiply the required gallons of
(4). Install jack pad kit (T201) on aft fuel by the fuel density to get
landing gear crosstube saddle assem required weight of fuel in pounds.
blies (ref. Section 07-10-00).
3). Weigh out this much fuel with
(5). Locate inclinometer (T203) on cabin scale (T808).
floor longitudinal axis between stations
155.00 and 213.00. 4). Add weighed fuel to fuel cell.
Page 626
TEMPERATURE, DEGREES C
-51 -40 -28 -17 -6 +4 +16 +27 +38 +49
958.51 8.0
WEIGHTS OF FUELS AT 60 F (15.6 C)
JP-4 6.38 POUNDS

(2.8965 kg) PER U.S. GALLON (3.785
LITERS)
897.67 7.5
JP-5 6.83 POUNDS
(3.100 kg) PER U.S. GALLON (3.785
LITERS)
SPECIFIC WEIGHT, LBS/U.S. GALS
JP-8, JET A, JET A-1 6.78 POUNDS

(3.078 kg) PER U. S. GALLON (3.785
837.82 LITERS)
7.0
DENSITY Kg/m3
JP-5
777.98 6.5 JET A, JET A-1, JP-8
EXAMPLE:
USE A THERMOMETER TO MEASURE THE
TEMPERATURE OF 1 U.S. GALLON (3.785
LITER) OF FUEL, EXAMPLE 80F (27C).
JP-4 INTERSECT THE 80F (27C) AND JET-A
MIL-T-5624 FUEL.
718.13 6.0 AT THE LEFT OF THE CHART, IDENTIFY
THE CORRESPONDING SPECIFIC WEIGHT,
IN THIS EXAMPLE 6.71 SPECIFIC WEIGHT.
6.71 X 2.6 U.S. GALLONS = 17.45 LBS OF
JET-A FUEL AT 80F (27C).
6.71 X 2.83 U.S. GALLONS = 18.99 LBS OF
JET-A FUEL AT 80F (27C).
658.29 5.5
-60 -50 -40 -30 -20 -10 0 10 20 30 40 50 60 70 80 90 100 110 120 130
TEMPERATURE, DEGREES F 9G28-033
Figure 608. Typical Fuel Density/Weight vs Temperature Fahrenheit/Celsius,

1 US Gallon/3.785 Liters
(11). Apply 24 to 28 Vdc external power to (a). Press the IIDS MENU key to bring
rotorcraft. up the top level menu display.
(12). Make sure that IIDS and FUEL 1). The display will show ELAPSE
PROBE circuit breakers on ESSEN TIME 00.
TIAL BUS panel and FUEL LOW
(900 CONFIG) or RH FUEL LOW and (b). Use the IIDS up arrow key or down
LH FUEL LOW (902 CONFIG) circuit arrow key to select FUEL CAL
breakers on ELECTRICAL LOAD IBRATION menu item.
CENTER panel are activated.
(13). Set POWER switch on ELECTRICAL (c). Press the IIDS ENT key for more
MASTER panel to BATT/EXT. than 4 seconds to bring up FUEL
CALIBRATION second level menu
(14). Make sure the red low fuel warning tick display.
marks flash.
1). The display will show SET CAL
(15). Do a fuel ``CALIBRATION on IIDS. CODE.
Page 627
(d). Use the IIDS up arrow key or down (18). Alternate Method:
arrow key to select DO CALIBRA
TION menu item. (a). Calculate fuel to be added by weight.
(e). Press the IIDS ENT key for more (b). Add an additional 18 US gal (68.137
than 4 seconds to bring up the DO L) to the fuel cell.
CALIBRATION third level menu.
(19). Make sure the FUEL low level warning
(f). The IIDS will display message: tick marks (red) indicators are not
illuminated.
AIRCRAFT READY ?
CRUISE ATTITUDE ? (20). Return the aircraft to normal ground
attitude (3 nose up).
(g). Press the IIDS ENT key for more
than 4 seconds to command calibra (21). Fuel the aircraft with an additional
tions. 128.2 US gal (485.28 L) of fuel from a
calibrated fuel truck metering system
(h). The IIDS will display calibration (ref. Section 12-00-00).
codes:
(22). Make sure the IIDS FUEL quantity
FWD FUEL CAL XXX LB is within:
AFT FUEL CAL XXX
Jet A, Jet A-1, JP-8: 932 to 1050 lb
(i). Record the fuel probe calibration (423 to 476 kg)
codes in the Rotorcraft Log Book for
future reference. JP-5: 939 to 1059 lb
(426 to 480 kg)
NOTE: Whenever the IIDS is replaced, the fuel
calibration codes must be re-entered into JP-4: 877 to 989 lb
the SET CAL CODE menu of the installed (398 to 449 kg)
IIDS (ref. CSP-900RMM-3, Section
95-30-00). (23). Alternative Method:
(j). Press the IIDS REC key to save the NOTE: This alternative method more accurate
calibration codes. ly finds that the indication falls within the
required +6% allowable error of actual fuel
(k). Press the IIDS CLR key to exit out
weight at full fuel.
of the menu.
(l). Set the POWER switch on ELEC (a). Find the actual fuel density in lb/gal
TRICAL MASTER panel to OFF for (kg/L) with a hydrometer.
10 seconds minimum. (b). Multiply the fuel density value by
NOTE: This will initialize the IIDS memory for 146.2 US gallons (553.4 L) (total
the calibration codes. usable fuel capacity) to find actual
usable fuel quantity in pounds
(16). Set the POWER switch on ELEC (kilograms).
TRICAL MASTER panel to BATT/
EXT. (c). The IIDS fuel quantity indication
must be within +6% of this value.
(17). Add an additional 18 US gal (68.137 L)
to the fuel cell as measured from a (24). On ELECTRICAL MASTER panel,
calibrated fuel truck metering system. set POWER switch to OFF.
Page 628
9. Tests for the Fuel Cell (5). Make sure the right FUEL low level
warning tick mark (red) indicator is
A. Integrity Test of the Longitudinal Baffle of illuminated.
the Fuel Cell (902 CONFIG)
(6). Make sure the left FUEL low level
warning tick mark (red) indicator is not
Aviation Turbine Fuel illuminated.
(7). Fuel must remain on left side of fuel
cell for 30 minutes without bleeding to
the right side.
(1). Make sure there is 60.0 US gal / 408.0 (a). Make sure the right FUEL low level
lb (227 L / 185 kg) of fuel in fuel cell warning tick mark (red) indicator
continues to be illuminated.
(2). Drain right side of fuel cell from RH (b). Make sure the left FUEL low level
fuel sump drain valve (forward drain warning tick mark (red) indicator is
valve control cable) into suitable not illuminated.
container.
(8). Set POWER switch on ELECTRICAL
(3). Apply 24 to 28 Vdc external power to MASTER panel to OFF.
aircraft.
(9). If longitudinal baffle integrity is not
kept, defuel the rotorcraft (ref. Section
(4). Make sure the IIDS and FUEL 12-00-00) and repair fuel cell (ref.
PROBE circuit breakers on ESSEN Manufacturer CMM, Section 01-00-00,
TIAL BUS panel and FUEL LOW or Section 28-00-00).
(900 CONFIG) or RH FUEL LOW and
LH FUEL LOW (902 CONFIG) circuit (10). If longitudinal baffle integrity is kept,
breakers on ELECTRICAL LOAD fuel the rotorcraft (ref. Section
CENTER panel are activated. 12-00-00).
Page 629
A
STRAIGHT EDGE
1.5 TO 1.7 INCH (38 TO 43 MM) 1.5 TO 1.7 INCH (38 TO 43 MM)
0.25 TO 0.50 INCH

(6.4 TO 12.7 MM)
SECTION A-A AFT VIEW 9G28-036A
Figure 609. Fuel Cell Baffle Cord Deflection (900 CONFIG)

10. Inspections for the Fuel Cell Baffle Cord (a). The cord cannot move more than
0.25 to 0.50 inch (6.4 to 12.7 mm)
A. Cord Deflection Inspection as measured perpendicular to the
lacing.
(b). If the cord is too loose (moves more
Consumable Materials than 0.50 inch (12.7 mm)), untie
(Ref. CSPSPM) and tie knot(s) again to increase
Item Nomenclature tension or replace the cord with nylon
C803 Nylon Cord, Braided cord (C803).
(c). If the cord is too tight (moves less

NOTE: A new fuel cell can have baffle support than 0.25 inch (6.4 mm)), untie and
cord routing that is too tight. This can lift tie knot(s) again to decrease tension
the fuel cell off the bottom of the cell cavity or replace the cord with nylon cord
when the fuel cell access covers are attached (C803).
to Access Panel A170.
(d). Tie the same knots as used before
(1). Put a straightedge across the fuel cell (bowline and half-hitch knots - ref.
cavity from the left keel beam flange to Figure 611).
the right keel beam flange.
(e). Make a note of the routing of a
(2). Support the fuel cell access cover removed cord and use the same
fittings so that they are 1.5 to 1.7 inch routing when you install the cord
(38 to 43 mm) below the bottom of the again.
straightedge.
(4). Seal cut cord ends with heat.
(3). Do a check of the cord tension between
the grommets and hangers. (5). Remove the straightedge.
Page 630
TOP
CORD 5 CORD 4
GROMMET (TYP)
AFT HANGER (TYP) FOR
BAFFLE WARD
0.25 TO 0.50 INCH
BAFFLE (6.4 TO 12.7 MM)
OPTIONAL
CORD 1 CENTER
END POINT BAFFLE
CORD
GROMMET (TYP)
CORD 2
18 INCH HANGER (TYP)
AFT BAFFLE
AND CORD 5
CORD 1
CORD 3 FORWARD BAFFLE
AND CORD 4
TOP VIEW, LOOKING DOWN

FILLER NECK
9g28-062A
Figure 610. Fuel Cell Baffles and Cord Routing (902 CONFIG)
Page 631
HANGER (TYP)
BOWLINE KNOT
TIGHTEN
TIGHTEN TIE
HALF-HITCH
KNOT
GROMMET (TYP)
9g28-081
Figure 611. Bowline and HalfHitch Knots
Page 632
11. Operational Tests for the Fuel Transfer (8). Install the filler cap (ref. Section
System (902 CONFIG) 12-00-00).
NOTE: The Normal Ground Attitude or the (9). Make sure the IIDS fuel quantity
Normal Cruise Attitude task can be done in display is between 173 and 213 lb
support of the Periodic Inspection or the (78.5 and 96.6 kg).
Segmented Inspection. (10). Make sure the right low fuel warning
A. Normal Ground Attitude (3 Degrees Nose tick mark is not illuminated.
Up, 0 Degrees Roll) The step that follows will arm
CAUTION the fire-extinguishing system.
(11). Set the left and right FUEL SHUT
OFF switches on FUEL SYSTEM
control panel to OFF.
NOTE: The operational ability of the transfer
system can be found with a flow rate measu
Special Tools
rement. This can be done by a time check of
(Ref. CSPSPM) the transfer of a known quantity of fuel.
Item Nomenclature
Stopwatch or Timer (12). Set the L BOOST switch on the FUEL
SYSTEM control panel to ON.
NOTE: The helicopter position must be on (13). Start the stopwatch or timer.
stable and level ground before you do this (14). The IIDS fuel quantity indication must
test. decrease.
(1). Attach the rotorcraft to an approved (15). Wait for the right low fuel warning tick
electrical ground (ref. Section mark to illuminate.
10-10-00).
(16). Immediately set the L BOOST switch
(2). Apply 24 to 28 Vdc external power to to OFF.
the rotorcraft (ref. Section 96-00-00). (17). Stop the stopwatch or timer.
(3). Make sure the IIDS, L BST PMP, R (18). The recorded time must be less than 10
BST PMP, RH FUEL LOW, and LH minutes.
FUEL LOW circuit breakers on the
ELECTRICAL LOAD CENTER panel (19). Set the R BOOST switch on the FUEL
are activated. SYSTEM control panel to ON.
(4). Make sure the IIDS, FUEL VLV R, (20). Start the stopwatch or timer.
FUEL VLV L, and FUEL PROBE (21). The IIDS fuel quantity indication must
circuit breakers on the ESSENTIAL increase.
BUS panel are activated.
(22). Wait for the left low fuel warning tick
(5). Set the POWER switch on ELEC mark to illuminate.
EXT. (23). Immediately set the R BOOST switch
to OFF.
(6). Remove the filler cap and secure the
lanyard in the slot provided in the filler (24). Stop the stopwatch or timer.
cap adapter. (25). The recorded time must be less than 10
minutes.
(7). Defuel the rotorcraft until the left red
low fuel warning tick mark illuminates (26). Set the POWER switch on the ELEC
(ref. Section 12-00-00). TRICAL MASTER panel to OFF.
Page 633
(27). Remove the 24 to 28 Vdc external (7). Make sure the IIDS, L BST PMP, R
power from the rotorcraft (ref. Section BST PMP, RH FUEL LOW, and LH
96-00-00). FUEL LOW, circuit breakers on the
ELECTRICAL LOAD CENTER panel
(28). Disconnect the electrical ground (ref. are activated.
Section 10-10-00).
(8). Make sure the IIDS, FUEL VLV R,
B. Normal Cruise Attitude (5 Degrees Nose FUEL VLV L, and FUEL PROBE
Down, 0 Degrees Roll) circuit breakers on the ESSENTIAL
BUS panel are activated.
Aviation Turbine Fuel (9). Remove the filler cap and secure the
lanyard in the slot provided in the filler
cap adapter.
(10). Defuel the rotorcraft until the left or
right red low fuel warning tick mark
Special Tools illuminates (ref. Section 12-00-00).
(Ref. CSPSPM) (11). Add 11.8 US gal (44.7 L) to the fuel
Item Nomenclature cell through the filler neck as measured
T201 Jack Pad Kit from a calibrated fuel truck metering
T202 Helicopter Jack system.
T203 Inclinometer (12). Install the filler cap (ref. Section
N/A Stopwatch or Timer 12-00-00).
The step that follows will arm
CAUTION the fire-extinguishing system.
NOTE: The helicopter position must be on
stable and level ground before you do this (13). Set the left and right FUEL SHUT
test. OFF switches on the FUEL SYSTEM
control panel to OFF.
(1). Attach the rotorcraft to an approved
electrical ground (ref. Section NOTE: The operational ability of the transfer
10-10-00). system can be found with a flow rate measu
rement. This can be done by a time check of
(2). Install jack pad kit (T201) on aft the transfer of a known quantity of fuel.
landing gear crosstube saddle assem
(14). Set the L BOOST switch on the FUEL
blies (ref. Section 07-10-00).
SYSTEM control panel to ON.
(3). Locate inclinometer (T203) on cabin (15). Start the stopwatch or timer.
floor longitudinal axis between stations
155.00 and 213.00. (16). The IIDS fuel quantity indication must
decrease.
(4). Use helicopter jack (T202) to jack the (17). Wait for the right low fuel warning tick
rotorcraft evenly to get a 5 nose down mark to illuminate.
ground attitude on the inclinometer
scale placed longitudinally on the cabin (18). Immediately set the L BOOST switch
floor, and level laterally across the to OFF.
cabin floor.
(19). Stop the stopwatch or timer.
(5). As necessary, stabilize the rotorcraft (20). The recorded time must be less than 6
with wooden blocks under the landing minutes.
gear skid tubes.
(21). Remove the filler cap and secure the
(6). Apply 24 to 28Vdc external power to lanyard in the slot provided in the filler
rotorcraft (ref. Section 96-00-00). cap adapter.
Page 634
(22). Wait 5 minutes. (29). Stop the stopwatch or timer.

(23). Install the filler cap (ref. Section (30). The recorded time must be less than 6
12-00-00). minutes.
(24). Set the R BOOST switch on the FUEL (31). Set the POWER switch on the ELEC
SYSTEM control panel to ON. TRICAL MASTER panel to OFF.
(25). Start the stopwatch or timer. (32). Remove 24 to 28 Vdc external power
(26). The fuel quantity indication on the from the rotorcraft (ref. Section
IIDS must increase. 96-00-00).
(27). Wait for left low fuel warning tick mark (33). Remove helicopter from wooden blocks
to illuminate. and jacks (ref. Section 07-10-00).
(28). Immediately set the R BOOST switch (34). Disconnect the electrical ground (ref.
to OFF. Section 10-10-00).
Page 635
12. Functional Tests for the Low Fuel Light (5). Set the POWER switch on the ELEC
A. Functional Test of the Low Fuel Light (900 EXT.
CONFIG)
Aviation Turbine Fuel (6). Defuel and drain the fuel cell sump of
all fuel with the rotorcraft at a normal
ground attitude (ref. Section 12-00-00).
(7). Make sure the FUEL low level warning

tick marks (red) indicators flash.
NOTE: The helicopter position must be on
stable and level ground before you do this (8). Add 18 US gal (68.1 L) to the fuel cell
test. as measured from a calibrated fuel
truck metering system.
(1). Attach rotorcraft to an approved
electrical ground (ref. Section (9). The FUEL low level warning tick
10-10-00). marks (red) indicators must not come
(2). Apply 24 to 28 Vdc external power to on or flash.
rotorcraft (ref. Section 96-00-00).
(10). Set the POWER switch on the ELEC
(3). Make sure the IIDS and FUEL TRICAL MASTER panel to OFF.
PROBE circuit breakers on the
ESSENTIAL BUS panel are activated. (11). Remove 24 to 28 Vdc external power
from the rotorcraft (ref. Section
(4). Make sure the FUEL LOW (900 96-00-00).
CONFIG) circuit breakers on the
ELECTRICAL LOAD CENTER panel (12). Disconnect the electrical ground (ref.
are activated. Section 10-10-00).
Page 636
FUEL SYSTEM
REPAIRS
1. Fuel Cell (a). Repairs can be done with approved
room temperature adhesives recom
A. General mended by the fuel cell manufactur
The fuel cell is an assembly constructed of er.
nitrile-coated woven nylon fabric inner-liner
(b). No patch is required unless the fabric
and outer-ply layers with an impervious,
in the adjacent area is torn, cut, or
0.002-inch-thick (0.05-mm-thick), nylon film
has holes through the cell layers.
barrier membrane put between the layers.
Since fuel cell repair materials, techniques, (2). Cord damage must have an applicable
and procedures can be changed or deleted by patch applied.
the fuel cell manufacturer without notice, B. InnerLiner/OuterPly Damage
MDHI cannot guarantee that the repair
procedures are up-to-date, complete, or (1). Inner-liner/outer-ply repairs that
technically accurate. require the use of cements, patches
Customers that do fuel cell repairs can order and/or vulcanization are:
manuals from the fuel cell manufacturer (a). Loose or open splice/lap seams.
before they start a repair task:
(b). Blisters or delaminations.
American Fuel Cells & Coated Fabrics Co.
(Amfuel, CAGE 05476) (c). Loose reinforcements or accessory
PO Box 887 601 Firestone Drive parts.
Magnolia, AR 71753 (USA)
Telephone: 870-234-3381 (d). Loose fitting flange.
Website: http://amfuel.com/
(e). Loose patches.
2. Fuel Cell Repair
C. Damage Limitations
Amfuel construction materials,
CAUTION repair methods and require (1). Fuel cells with these conditions must be
ments, supplies, and materials are not com returned to the manufacturer for
patible or interchangeable with other fuel inspection to find if the fuel cell can be
cell manufacturers. repaired:
A. Scuff Mark, Chafing, or Snag Damage (a). Inner-liner nylon barrier damage.
(1). Scuff marks, chafing, or snag damage (b). Holes through a cell wall or fitting
on one of the two inner-liner layer or flange.
outer-ply layer (example: layer miss
ing, exposed cord not-damaged) and (c). Replacement of fitting assemblies.
adjacent area can be buffed, cleaned,
have a layer of cement applied, and be (d). Indications of activation or chemical
air-dried for 8 hours. reactions (self-sealing cells).
Page 801
Page 802
Section
281000
Supplemental Fuel
System (Option)
SUPPLEMENTAL FUEL SYSTEM (OPTION)

1. General CURRENT CONFIG - A one way check valve
internal to the supplemental fuel tank
(Ref. Figure 1) prevents fuel from flowing from the supple
mental fuel tank to the main fuel tank when
The supplemental fuel system installs an the transfer pump is not on.
auxiliary fuel tank of thirty U.S. gallons
(113.56 liters) underneath the baggage floor.
A one way check valve internal to the main
The tank is filled through a gravity fill port
tank prevents fuel from flowing to the supple
located on the right side of the helicopter,
mental tank. Main fuel tank fuel level is
approximately two feet (0.61 M) aft of the
controlled by a float activated shut off valve.
cabin door opening, and approximately five
The shut off valve is attached to the underside
inches (0.127 M) above the baggage floor.
of the aft LH main fuel tank access panel with
an aluminum bracket and bolts.
2. Supplemental Fuel Tank Installation
(Ref. Figure 1) The shut off valve allows fuel transfer when
the main fuel tank quantity is less than
The area within the boattail tub, aft of FS ninety-four U.S. gallons (355.83 liters) and
230.5, between the LH and RH keel beams, inhibits transfer when the main tank fuel
and under the baggage floor is sealed to quantity is greater than one hundred and
provide a fuel and vapor tight fuel cell cavity. eleven U.S. gallons (420.18 liters).
Blocks of rigid closed cell foam are installed in
unused areas to provide support for the fuel
4. Supplemental Fuel System Fuel Vent
tank on the sides and bottom.
The top of the supplemental tank is supported (Ref. Figure 1)

by an aluminum hat support which is bolted to
the fuel tank access cover. The hat support is
The supplemental fuel system vent incorpo
bolted at FS 230.5 and FS 257 to aluminum
rates a single vent/rollover valve attached to
gusset supports which are attached by rivets.
the fuel tank access cover. This valve allows
The fuel tank is attached by bolts to the RH
venting during normal operation and closes in
keel beam at the filler neck attachment.
a rollover to prevent fuel from draining from
the fuel tank. Aluminum vent tubing is routed
3. Supplemental Fuel System Fuel Supply forward and along the front of the supplemen
tal tank to tee into the RH main tank vent
(Ref. Figure 1) system.
Fuel is transferred into the main tank by an
electrically operated fuel transfer pump 5. Supplemental Fuel System Fuel Quantity
mounted to the bottom of the supplemental
fuel tank with bolts. The fuel pump is con
(Ref. Figure 1)
trolled by a toggle switch mounted in the
cockpit. An indicator light mounted in the
cockpit illuminates when the toggle switch is Supplemental fuel quantity is indicated by an
in the on position. analog fuel gauge mounted on the instrument
panel in the cockpit. The fuel quantity
Fuel is transferred to the main fuel tank transducer is a float type and is mounted to
through a fitting in the aft left vent/rollover the supplemental fuel tank access cover with
valve mounting plate. screws.
Page 1
FUEL VENT VALVE
FUEL VENT FLOAT/ROLLOVER VALVE

SUPPLEMENTAL FILLER NECK
FUEL QUANTITY TRANSMITTER
SUPPLEMENTAL FUEL CELL

EXISTING MAIN FUEL CELL
FUEL TRANSFER LINE
FUEL TRANSFER LINE
FUEL LEVEL CONTROL VALVE
9G28-064-1
Figure 1. Supplemental Fuel System Installation (Sheet 1 of 2)
Page 2
Revision 1 28-10-00
FUEL TRANSFER LINE ELBOW 230.5 BULKHEAD AIRCRAFT DML

EXISTING AUX FUEL PORT
ON MAIN FUEL CELL CHECK VALVE BAGGAGE FLOOR
EXISTING AFT/RIGHT VENT FLOAT/
FUEL TRANSFER LINE ACCESS COVER
ROLLOVER VALVE ON MAIN FUEL CELL
(AUX-MAIN)
CABIN FLOOR VENT FLOAT/
VENT LINE ROLLOVER VALVE
EXISTING MAIN
FUEL CELL AFT/
LEFT ACCESS COVER FUEL TRANSFER LINE
EXISTING MAIN
FUEL CELL
GRAVITY FILL PORT
LEVEL CONTROL CHECK VALVE
VALVE SUPPORT GRAVITY FILL PORT
EXISTING AFT/RIGHT VENT LINE SUPPLEMENTAL

LEVEL CONTROL VALVE FUEL CELL
EXISTING AFT FLAME ARRESTOR FUEL FUEL QUANTITY
TRANSFER
LINE TRANSMITTER (FLOAT)
EXISTING AFT VENT FAIRING
CHECK VALVE TRANSFER PUMP
( CURRENT CONFIGURATION )
SUMP DRAIN PLUG
9G28-064-2
Page 3
Page 4

FAULT ISOLATION
1. Supplemental Fuel System The troubleshooting tables should be used
Troubleshooting with the simplified system schematics,
electrical wiring diagrams, serviceability
(Ref. Figure 101) checks and other detailed procedures in this
and other chapters of the manual.
brief summary of supplemental fuel system Comprehensive wiring diagrams are available
faults which may be encountered. in Section 98-40-00.

Fuel does not transfer into Faulty wiring between switch Test and repair wiring 206000
main tank with transfer and transfer pump
switch on and transfer light
Illuminated
Faulty ground on transfer Inspect pump bonding jumper CSPSPM

pump and ensure a class C electrical
bond
Obstruction in supplemental Remove supplemental fuel 281000
fuel transfer system transfer system components as
required to remove obstruction
Faulty fuel level control valve Replace fuel level control valve 281000
Faulty transfer pump Replace transfer pump 281000
Fuel does not transfer into Faulty wiring between AUX Test and repair wiring 206000
main tank with transfer FUEL circuit breaker and
switch on and transfer light switch
Not Illuminated
Faulty circuit breaker Replace circuit breaker 960000

Faulty switch Replace switch 960000
Transfer light does not Faulty wiring between Test and repair wiring 206000
illuminate when transfer transfer switch and transfer
switch is in the on position, light
fuel does transfer
Faulty transfer light Replace transfer light 281000

Fuel tank slow to fuel, Obstruction in fuel vent Remove vent system 281000
possibly some fuel spray system components as required to
back from filler neck remove obstruction
Obstruction in fuel filler neck Remove filler neck and remove 281000
obstruction
Faulty gravity fill check valve Replace check valve 281000
Page 101
Table 101. Troubleshooting (Cont.)

Fuel quantity indicator Faulty wiring between Test and repair wiring 980000
indicates EMPTY when fuel quantity transmitter and
is in supplemental fuel tank quantity indicator
Faulty wiring between AUX Test and repair wiring 980000
FUEL XMIT circuit breaker
and indicator
Faulty indicator Replace indicator 950000
Faulty transmitter Replace transmitter 281000
Fuel quantity indicator Faulty transmitter Replace transmitter 281000
indicates inaccurately
Faulty indicator Replace indicator 950000

Uncommanded fuel transfer Check valve not installed in Install check valve 281000
from supplemental to main suppelmental tank
tank
Faulty check valve in Replace replace check valve 281000
supplemental tank
A620 CENTER CONSOLE A310

ELECTRICAL LOAD CENTER AUX FUEL PUMP
SI
CB33 OFF
AUX J2 P374 1 P537 J1
FUEL
5A 52 A (+) 28VDC
ON 3
BATT BUS 4 AUX FUEL GS300-A E C M PUMP MTR
XFER
GS300-B E B (-) GRD
CB61
AUX DSI
FUEL XMIT - +
1A 46 E
GS110-A FUEL XFER PUMP
INDICATOR LT
A612
INSTRUMENT PANEL
FWD INTERCON PANEL
DS2 SP1 P118 J118 TB3-1 TB2-9
DS2
- +
40 D CB A HG FE
NOTE 1
AUX FUEL QTY
IND LT
AUX FUEL QTY A311

IND AUX FUEL QTY TRANSMITTER
IGN (+ 28VDC) 53
SEND 54 (+) 28VDC
GROUND (-) 55 E E (-) GROUND
GS109-E GS300-C
NOTE: WIRE BETWEEN TB3-1A AND TB2-9H MAY BE DIFFERENT, DEPENDING ON OTHER INSTALLATIONS 9G28-069A
Figure 101. Supplemental Fuel System Wiring Diagram
Page 102

REMOVAL AND INSTALLATION
1. Supplemental Fuel Transfer Pump (12). Remove fitting (7) and packing (73)
(Ref. Figure 403) from transfer pump
A. Supplemental Fuel Transfer Pump and discard packing.
Removal
B. Supplemental Fuel Transfer Pump
(Ref. Figure 401 and Figure 403) Installation
(1). Defuel supplemental fuel tank (Ref. (Ref. Figure 401 and Figure 403)
Section 12-00-00).
(2). Remove baggage compartment floor Consumable Materials
(Ref. Section 53-20-00). (Ref. CSPSPM)
Item Nomenclature
(3). Remove bolts (18), washers (19), bolts C702 Lockwire
(33), and washers (34) and remove hat C113 Fuel, Aviation Turbine
support channel (17) (Ref. Figure 403).
(4). Disconnect electrical connector (27)
from top of fuel tank cover (20). Special Tools
(Ref. CSPSPM)
Aviation Turbine Fuel Item Nomenclature

(5). Remove quantity transmitter.
(6). Remove lockwire (32) and slide hose
(31) to expose end of vent tube (35).
NOTE: Lubricate new packing with aviation
NOTE: Use care when removing fuel tank cov turbine fuel (C113).
er, transfer pump wire harness has approxi
mately 10 in. (25.4 cm) of excess length. (1). Install new packing onto transfer pump
fitting and install fitting. Torque fitting
(7). Remove bolts (25) and washers (26). (Ref. CSP-SPM).
Remove fuel tank cover (20). Remove
and discard packing (21). (2). Position transfer pump in fuel tank and
install bonding jumper and mounting
(Ref. Figure 401) bolts. Torque bolts (Ref. CSP-SPM).
(8). Straighten tab on lockwasher (6) and (3). Using milli-ohm meter (T1002), test
remove jam nut (5) and lockwasher. transfer pump for a class C electrical
Discard lockwasher. bond (Ref. CSP-SPM). Environmental
seal is not required.
(9). Remove connector (8) from cover (7).
(4). Attach fuel transfer hose to transfer
(10). Disconnect fuel transfer hose (5) from pump. Torque hose (Ref. CSP-SPM).
transfer pump fitting (7) (Ref.
Figure 403). (5). Install transfer pump wire harness
connector into fuel tank cover and install
(11). Remove bolts (2), washers (3), (Ref. lockwasher and nut. Torque nut to 120
Figure 401) and remove pump (1) from to 150 in lb. (13.56 to 16.95 Nm) and
fuel tank. bend up tab on lockwasher.
Page 401
28-10-00 Revision 1
(6). Install new packing into groove on top

5
of fuel tank and install cover. Install 6
and torque bolts (Ref. CSP-SPM).
LBL
(7). Install quantity transmitter. 1 7.81
(8). Slide vent hose to equally cover gap 7

between vent tubes and install lockwire 8
(C702)
4
(9). Connect wire harness to transfer pump 2 (3PL)

connector. 3 (3PL)
(10). Install support hat channel. Torque

bolts (Ref. CSP-SPM).
WL
(11). Install baggage floor (Ref. Section 93.407
53-20-00).
9G28-074
1. TRANSFER PUMP
(12). Perform supplemental fuel tank 2. BOLT
leak/pressure test. 3. WASHER
4. BONDING JUMPER
5. JAM NUT
(13). Perform supplemental fuel quantity 6. LOCKWASHER
operational test. 7. COVER
8. CONNECTOR
(14). Service fuel tank as required (Ref. Figure 401. Supplemental Fuel Transfer
Section 12-00-00). Pump
Page 402
Revision 1 28-10-00
2. Supplemental Fuel Tank Filler Neck B. Supplemental Fuel Tank Filler Neck
Adapter Adapter Installation
(Ref. Figure 402)
A. Supplemental Fuel Tank Filler Neck
Adapter Removal Consumable Materials
(Ref. CSPSPM)
Item Nomenclature
C113 Fuel, Aviation Turbine
(1). Defuel supplemental fuel tank (Ref.
Section 12-00-00).
Special Tools
(Ref. CSPSPM)
(2). Remove baggage compartment floor Item Nomenclature
(3). Remove bolts (63 and 65) and washers Aviation Turbine Fuel
(64 and 66) attaching supplemental fuel
filler neck cover (61) (Ref. Figure 403).
(4). Remove sealant from around periphery

of filler neck cover. Remove cover. NOTE: Lubricate new packing with aviation
turbine fuel (C113).
(1). Install new packing onto filler neck
(5). Remove right side baggage floor panel adapter.
NOTE:
If may be necessary to remove supple
(6). Remove bolt (5), washers (6), nut (7), mental fuel tank cover and assist filler
and clamp (12) (Ref. Figure 402) from neck adapter alignment from within fuel
filler neck. tank.
Shop aides may be fabricated by removing
Aviation Turbine Fuel the heads from two (2) 1/4-28 bolts with
approximately 3 in. (7.62 cm) shanks. Ra
dius and deburr ends. Install shop aides
into two (2) lower adapter attach holes
through keel beam and thread into inserts
in fuel tank, hand tighten. After position
ing filler neck adapter, pull shop aides out
(7). Loosen hose clamps (16) and slide hose board and start the upper attach bolts. Re
(13) up on filler neck (2) to expose tank move shop aides and continue installation.
adapter (14). (2). Align filler adapter mounting holes
with holes in keel beam and inserts in
fuel tank.
attaching adapter (14) to fuel tank. (3). Install filler adapter mounting bolts
and bonding jumper. Torque bolts (Ref.
CSP-SPM).
(9). Remove adapter (14) from fuel tank.
(4). Slide filler hose centered over gap
between filler adapter and filler neck.
(10). Remove and discard packing (21). Torque hose clamps (Ref. CSP-SPM).
Page 403
28-10-00 Revision 1
(5). Install screw, washers, nut, and (2). Pull gravity fill check valve (19) from
bonding jumpers to filler neck. fuel tank through keel beam and
remove.
(6). Using milli-ohm meter (T1002), test
filler adapter for a class S electrical (3). Remove packing (20) and discard.
bond (Ref. CSP-SPM). Environmental
seal is not required. B. Supplemental Fuel System Gravity Fill
Check Valve Installation
(7). Install center baggage floor panel (Ref.
(Ref. Figure 402)
Section 53-20-00).
(8). Perform supplemental fuel tank Consumable Materials
leak/pressure test. (Ref. CSPSPM)
Item Nomenclature
(9). Install right side baggage floor panel
(Ref. Section 53-20-00). C113 Fuel, Aviation Turbine
(10). Position supplemental fuel tank filler

neck cover and install bolts and Special Tools
washers. Torque bolts (Ref. CSP-SPM).
(Ref. CSPSPM)
Solvent Cleaner (C429) Item Nomenclature

(11). Clean edge of filler neck cover and
adjacent structure with solvent cleaner (1). Install new packing onto gravity fill
(C429) and allow to air dry for fifteen check valve.
(15) minutes.
(2). Temporarily install filler neck adapter
Sealant, Fuel Resistant (C216) bolts and bonding jumper hand tight to
hold tank in position during check valve
installation.
(3). Install gravity fill check valve through
keel beam and into fuel tank. Ensure
(12). Apply a bead of sealant (C216) around check valve is fully seated in fuel tank.
entire periphery of filler neck cover.
(4). Remove filler neck adapter mounting
(13). Service fuel tank as required (Ref. bolts.
Section 12-00-00).
NOTE: Prior to installing floor panel, remove
3. Supplemental Fuel System Gravity Fill fuel tank cover and perform bond test in ac
Check Valve cordance with step (6). Reinstall fuel tank
cover.
A. Supplemental Fuel System Gravity Fill
Check Valve Removal (5). Install filler neck adapter.
(Ref. Figure 402) (6). Using milli-ohm meter (T1002), test

gravity fill check valve for a class S
(1). Remove Fuel Tank Filler Neck Adapter electrical bond (Ref. CSP-SPM).
(14). Environmental seal is not required.
Page 404
Revision 1 28-10-00
4. Supplemental Fuel System Filler Neck B. Supplemental Fuel System Filler Neck
Installation
A. Supplemental Fuel System Filler Neck
Removal (Ref. Figure 402)
(Ref. Figure 402)
Special Tools
(1). Defuel supplemental fuel tank (Ref. (Ref. CSPSPM)
(2). Remove baggage compartment floor T1002 MilliOhm Meter
(3). Remove bolts (63 and 65) and washers (1). Align filler neck mounting flange with
(64 and 66) attaching supplemental fuel hole in fuselage and install screws and
filler neck cover (61) (Ref. Figure 403). washers. Torque screws (Ref. CSP-
SPM).
(4). Remove sealant from around periphery
of filler neck cover. Remove cover. (2). Slide filler hose centered over gap
between filler adapter and filler neck.
(5). Remove right side baggage floor panel Torque hose clamps (Ref. CSP-SPM).
(3). Install screw, washers, nut, clamp, and
(6). Remove bolt (5), washers (6), nut (7), bonding jumpers to filler neck.
bonding jumpers (8), and clamp (12)
from filler neck (2). (4). Using milli-ohm meter (T1002), test
gravity fill check valve for a class S
Aviation Turbine Fuel electrical bond (Ref. CSP-SPM).
Environmental seal is not required.
(5). Install center baggage floor panel (Ref.
Section 53-20-00).
(7). Loosen hose clamps (16) and slide hose (6). Perform supplemental fuel tank
(13) up on filler neck (2) to expose tank leak/pressure test.
adapter (14).
(7). Install right side baggage floor panel
(8). Remove bolts (3) and washers (4) from (Ref. Section 53-20-00).
filler neck mounting flange.
(8). Position supplemental fuel tank filler
(9). Remove nut ring assembly (18) and neck cover and install bolts and
filler neck (2). washers. Torque bolts (Ref. CSP-SPM).
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28-10-00 Revision 1
1
2 3 (8PL)
18
4 (8PL)
2
5
2X 6
7
21
8 (2PL)
12 16 (2PL)
20
13
19
14
9
2X 10 WL
11 101.110
14
15
17
15 (4PL) RH KEEL BEAM REF

17 (4PL)
FS 9B28-067
244.532
1.
CAP, FUEL, GRAVITY FILL PORT 11. NUT, SELF LOCKING
2.
NECK, FUEL GRAVITY FILL PORT 12. CLAMP, LOOP TYPE, BONDING
3.
BOLT, PAN HEAD, CLOSE TOLERANCE 13. HOSE, FUEL, GRAVITY FILL PORT
4.
WASHER, FLAT 14. TANK ADAPTER, FUEL, GRAVITY FILL PORT
5.
BOLT, PAN HEAD, CLOSE TOLERANCE 15. BOLT, HEX HEAD, CLOSE TOLERANCE
6.
WASHER, FLAT 16. CLAMP, HOSE
7.
NUT, SELF LOCKING 17. WASHER, FLAT
8.
JUMPER ASSEMBLY, BONDING AND CURRENT 18. NUT RING ASSEMBLY
RETURN 19. CHECK VALVE, FUEL, GRAVITY FILL PORT
9. BOLT, HEX HEAD, CLOSE TOLERANCE 20. PACKING, PREFORMED
10. WASHER, FLAT 21. PACKING, PREFORMED
Figure 402. Supplemental Fuel System Filler Neck
5. Supplemental Fuel System Quantity (3). Remove nut (40) and washer (68)
Transmitter disconnect electrical lead from top of
quantity transmitter (28).
A. Supplemental Fuel System Quantity
Transmitter Removal NOTE:
It is necessary to angle the transmitter
(Ref. Figure 403) during removal to allow the float arm to
be retracted through the opening in the
fuel tank.
Section 12-00-00).
Quantity transmitter mounting holes are
(2). Remove baggage compartment floor non-symmetrical and arm is clocked at
(Ref. Section 53-20-00). the 9:30 position at installation.
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Revision 1 28-10-00
Aviation Turbine Fuel 6. Supplemental Fuel Tank Cover
A. Supplemental Fuel Tank Cover Removal
(Ref. Figure 403)

(4). Remove screws (29) and washers (67) (1). Defuel supplemental fuel tank (Ref.
from fuel quantity transmitter (28) and Section 12-00-00).
lift transmitter from tank.
(5). If gasket (74) is unserviceable, remove (Ref. Section 53-20-00).
and discard gasket.
(3). Remove bolts (18 and 33) and remove
B. Supplemental Fuel System Quantity hat support channel (17).
Transmitter Installation
(4). Disconnect electrical connection (27),
(Ref. Figure 403) and nut (40) from top of fuel tank cover
(20). Remove wire from quantity
NOTE: transmitter (28).
It is necessary to angle the transmitter
during installation to allow the float arm Aviation Turbine Fuel
to be inserted through the opening in the
fuel tank.
Quantity transducer mounting holes are
non-symmetrical and arm is clocked at
the 9:30 position at installation. (5). Remove quantity transmitter (28).
Ensure float or float arm does (6). Remove lockwire (32) and slide hose
CAUTION not become entangled in inter (31) to expose end of vent tube (35).
nal wiring or damaged by contact with in
ternal components during installation. (7). Remove bolts (23), washers (24), and
remove bonding jumper (30) from fuel
(1). Install gasket onto transmitter and vent fitting (22).
align with mounting holes.
(8). Remove fuel vent fitting (22) and
(2). Insert float and float arm through packing (75). Discard packing.
opening in fuel tank.
NOTE: Use care when removing fuel tank cov
(3). Install screws and washers. Torque er, transfer pump wire harness has approxi
screws (Ref. CSP-SPM). mately 10 in. (25.4 cm) of excess length.
(4). Install electrical lead onto quantity (9). Remove bolts (25) and washers (26) and
transmitter and install nut. Torque nut remove fuel tank cover(20). Remove
(Ref. CSP-SPM). and discard packing (21).
(5). Install baggage floor (Ref. Section (10). Straighten tab on lockwasher (6) and
53-20-00). remove jam nut (5) and lockwasher (6).
Discard lockwasher (Ref. Figure 401).
(6). Perform supplemental fuel tank
leak/pressure test. (11). Remove connector (8) from cover (7)
(Ref. Figure 401).
(7). Perform supplemental fuel quantity
operational test. (12). Remove retaining ring (76) and wave
washer (9) and remove vent/rollover
(8). Service fuel tank as required (Ref. valve (2) from cover. Remove packing
Section 12-00-00). (3) and discard.
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28-10-00 Revision 1
B. Supplemental Fuel Tank Cover (9). Install quantity transmitter.

Installation
(10). Slide vent hose to equally cover gap
(Ref. Figure 403) between vent tubes and install lockwire
(C702)
Consumable Materials (11). Connect wire harness to transfer pump
(Ref. CSPSPM) connector.
Item Nomenclature
C702 Lockwire (12). Install support hat channel. Torque
bolts (Ref. CSP-SPM).
C113 Fuel, Aviation Turbine
(13). Install baggage floor (Ref. Section
53-20-00).
Special Tools
(14). Perform supplemental fuel tank
(Ref. CSPSPM)
leak/pressure test.
Item Nomenclature
T1002 MilliOhm Meter (15). Perform supplemental fuel quantity
operational test.
(1). Install transfer pump wire harness (16). Service fuel tank as required (Ref.
connector into fuel tank cover and Section 12-00-00).
install lockwasher and nut. Torque nut
to 120 to 150 in lb. (13.56 to 16.95 7. Supplemental Fuel Tank
Nm) and bend up tab on lockwasher.
A. Supplemental Fuel Tank Removal
(Ref. Figure 403)
(1). Remove supplemental fuel tank filler
adapter.
NOTE: Lubricate new packings with aviation (2). Remove foam support (10) (Ref.
turbine fuel (C113). Figure 404).
(2). Install new packing onto vent/rollover (3). Disconnect fuel transfer hose (49) from
valve and install valve into cover. supplemental fuel tank (4) (Ref.
Figure 403). Cap and plug open
(3). Install wave washer and retaining ring. connections.
(4). Install new packing into top of vent/rol (4). Remove bolts (18), washers (19), bolts
lover valve and install vent fitting. (33), and washers (34) and remove hat
support channel (17).
(5). Install bolts, washers,and bonding
jumper. Torque bolts (Ref. CSP-SPM). (5). Disconnect electrical connector (27) and
nut (40) washer (68) and wire from top
(6). Using milli-ohm meter (T1002), test of fuel tank cover (20).
vent/rollover valve for a class S electri
cal bond (Ref. CSP-SPM). Environmen (6). Remove lockwire from vent hose (31)
tal seal is not required. and separate vent tube (35) from vent
hose (31).
(7). Install new packing into groove on top
of fuel tank and install cover. Install (7). From underside of boattail tub, push up
and torque bolts (Ref. CSP-SPM). on fuel tank adjacent to plug (50) to
loosen the hook and loop attachment
(8). Using milli-ohm meter (T1002), test (72).
fuel tank cover for a class C electrical
bond (Ref. CSP-SPM). Environmental (8). Carefully lift fuel tank vertically from
seal is not required. fuel tank cavity.
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Revision 1 28-10-00
B. Supplemental Fuel Tank Installation packing. Do not allow sealant to

protrude above packing.
(Ref. Figure 403)
(8). Allow sealant to cure completely prior
to installing fuel tank.
(Ref. CSPSPM) (9). Carefully lower fuel tank into cavity
Item Nomenclature aligning drain plug with drain hose.
C429 Solvent Cleaner
(10). Insert vent tube into vent hose and
C411 Adhesive, Epoxy install two wraps of lockwire (C702)
C702 Lockwire (11). Thread loose ends of nylon cord through
ferrule on fuel tank and lacing brack
ets. Secure cord with truckers knot.
(1). Thoroughly clean fuel tank cavity and
remove any foreign objects. (12). Connect fuel transfer hose to fuel tank
fitting. Torque hose (Ref. CSP-SPM).
(2). Ensure packing (54) is installed and
has a fillet of sealant around the inside (13). Install foam support (10) (Ref.
and outside periphery. If necessary Figure 404).
replace packing. (14). Position fuel tank support hat channel
(3). Remove packing, sealant fillets, and over fuel tank and install bolts into fuel
epoxy bond material. tank cover. Torque bolts (Ref. CSP-
SPM).
Solvent Cleaner (C429)
(15). Install mounting bolts at the forward
and aft end of the support hat channel.
Torque support bolts (Ref. CSP-SPM).
(16). Install fuel filler neck adapter.
(4). Clean surface of sump support (53) and
packing with solvent cleaner (C429) 8. Supplemental Fuel Check Valve
and allow to air dry for fifteen (15) (CURRENT CONFIG)
minutes.
A. Supplemental Fuel Check Valve Removal
Adhesive, Epoxy (C411) (Ref. Figure 403)
Section 12-00-00).
(5). Center packing over drain hole in sump
support and bond in place with epoxy
adhesive (C411) and allow to cure. (3). Remove bolts (18), washers (19), bolts
(33), and washers (34) and remove hat
(6). Clean surface of sump support and support channel (17) (Ref. Figure 403).
packing with solvent cleaner (C429)
and allow to air dry for fifteen (15) (4). Disconnect electrical connector (27)
minutes. from top of fuel tank cover (20).
Sealant, Fuel Resistant (C216) Aviation Turbine Fuel
(7). Apply a fillet of sealant (C216) to the (5). Remove lockwire (32) and slide hose
inner and outer periphery of the (31) to expose end of vent tube (35).
Page 409
NOTE: Use care when removing fuel tank cov (1). Install new check valve with new
er, transfer pump wire harness has approxi packing on bulkhead tube fitting.
mately 10 in. (25.4 cm) of excess length. Torque check valve (Ref. CSP-SPM).
Remove fuel tank cover (20). Remove (2). Using milli-ohm meter (T1002), test
and discard packing (21). check valve for a class S electrical bond
(Ref. CSP-SPM).
(7). Disconnect pump to auxiliary cell outlet
hose (77) from check valve (80).
(3). Attach pump to auxiliary cell outlet
(8). Remove check valve from bulkhead hose to check valve. Torque hose (Ref.
tube fitting (48) and discard packing CSP-SPM).
(79).
B. Supplemental Fuel Check Valve (4). Install new packing into groove on top
Installation of fuel tank and install cover. Install
and torque bolts (Ref. CSP-SPM).
(Ref. Figure 403)
(5). Slide vent hose to equally cover gap
(Ref. CSPSPM)
between vent tubes and install lockwire
Item Nomenclature
(C702)
C702 Lockwire
C113 Fuel, Aviation Turbine (6). Connect wire harness to transfer pump
connector.
Special Tools (7). Install support hat channel. Torque

(Ref. CSPSPM) bolts (Ref. CSP-SPM).
Item Nomenclature
T1002 MilliOhm Meter (8). Install baggage floor (Ref. Section
53-20-00).
Upon installation of check
CAUTION valve, insure arrow on valve (9). Perform supplemental fuel tank
points in direction of fuel flow in system. leak/pressure test.
(10). Perform supplemental fuel quantity
operational test.
(11). Service fuel tank as required (Ref.

NOTE: Lubricate new packing with aviation Section 12-00-00).
Page 410
12
11
18
19 10
RH KEEL BEAM REF

5
77
17
16
15 4
6
37 14
38 X 2 FS 30
235.532 7
39
73
13 8 (3PL)
23 (2PL)
36 24 (2PL)
31 (2PL) 22 42 (2PL)
43 2X (2PL)
20
RBL 44 (2PL)
21 35
35 24.000
25 (20PL)
26 (20PL) 32 (2PL)
BL
0.000 10-12 in-lb
40
1.13-1.36 Nm
68
32 (4PL) 31
41
33 (4PL) 28
34 (4PL) 74 WL 45
94.157
27
29 (5PL) 46
67 (5PL) 32 (4PL)
32 (4PL)
9G28-065-1
Page 411
FS
235.50
54
53 55
SUPPLEMENTAL 72
FUEL TANK 47
69 LOOKING DOWN
FS
230.50
48
49 70
53
LBL
12.000
EARLY CONFIGURATION
LOOKING DOWN
52 51
14
LOOKING INBOARD LH SIDE
77
LBL
79 9.160
80
47
SUPPLEMENTAL 69
FUEL TANK FS
FS 243.632
230.500 50
70 78 71
48 LOOKING UP
49
LBL
12.000
LOOKING DOWN
9G28-065-2A
Page 412
FS
230.50
RH KEEL BEAM REF
56 (2PL)
57
61
58 REF
LOOKING OUTBOARD RH SIDE
57
58 (6PL)
59 (6PL)
63 60 (6PL)
64
RBL
75 24.00
76
9
WL
65
104.21
66
3
62
RBL
24.00
9G28-065-3
Page 413

1. NECK, FUEL, GRAVITY FILL PORT 43. WASHER, FLAT
2. VALVE, VENT/ROLLOVER 44. NUT, SELF LOCKING
3. PACKING, PREFORMED 45. TEE, FUEL VENT
4. TANK, SUPPLEMENTAL FUEL 46. JUMPER ASSEMBLY, BONDING AND CURRENT
5. HOSE, TRANSFER, PUMP TO TANK FITTING (EARLY RETURN
CONFIG) 47. NUT, TUBE, BULKHEAD FITTING
6. PUMP, TRANSFER 48. FITTING, TUBE, BULKHEAD
7. FITTING, PUMP TO HOSE 49. HOSE ASSEMBLY, FUEL TRANSFER, SUPPLEMENTAL
8. BOLT, HEX HEAD, CLOSE TOLERANCE TANK TO MAIN TANK
9. WAVE WASHER, VENT VALVE 50. PLUG, DRAIN, SCREW THREAD
10. FOAM SUPPORT, AFT, OUTBOARD, LH 51. DRAIN HOSE, SUPPLEMENTAL FUEL
11. FOAM SUPPORT, AFT, INBOARD, LH 52. CLAMP, HOSE
12. FOAM SUPPORT, AFT, RH 53. SUPPORT, FUEL TANK SUMP
13. FOAM SUPPORT, LOWER, LH 54. PACKING, PERFORMED, ORING
14. FOAM SUPPORT, LOWER, SUMP 55. HOSE ADAPTER
15. FOAM SUPPORT, LOWER, CENTER 56. DOUBLER, KEEL BEAM WEB
16. FOAM SUPPORT, LOWER, RH 57. CLOSEOUT, LOWER FUEL
17. CHANNEL, HAT SUPPORT
58. BRACKET
18. BOLT, CLOSE TOLERANCE
59. SCREW, HEX HEAD, CRUCIFORM RECESS
19. WASHER
60. WASHER, FLAT
20. COVER, SUPPLEMENTAL FUEL TANK
61. COVER, NECK, FUEL, GRAVITY FILL PORT
21. PACKING
62. PANEL, BAGGAGE FLOOR, RH OUTBOARD,
22. FITTING, FUEL VENT
MODIFIED
23. BOLT, HEX HEAD, CLOSE TOLERANCE
24. WASHER, FLAT
64. WASHER, FLAT
25. BOLT, HEX HEAD, CLOSE TOLERANCE
26. WASHER, FLAT
27. CONNECTOR, FUEL TRANSFER PUMP 66. WASHER, FLAT
28. FUEL QUANTITY TRANSMITTER 67. PACKING WITH RETAINER
29. SCREW, HEX HEAD, CRUCIFORM RECESS 68. WASHER, LOCKING
30. JUMPER ASSEMBLY, BONDING AND CURRENT 69. WASHER, FLAT
RETURN 70. WASHER, SEALING
31. HOSE, CONNECTION, FUEL VENT 71. PACKING, PREFORMED
32. LOCKWIRE 72. HOOK OR PILE TO MATE WITH BOTTOM OF
33. BOLT, HEX HEAD, CLOSE TOLERANCE SUPPLEMENTAL FUEL TANK
34. WASHER, FLAT 73. PACKING, PREFORMED
35. TUBE ASSEMBLY, FUEL VENT 74. GASKET, FUEL QUANTITY TRANSMITTER
36. CLAMP, LOOP TYPE, BONDING 75. PACKING PREFORMED
37. BOLT, PAN HEAD, CLOSE TOLERANCE 76. RING, RETAINING, VENT VALVE
38. WASHER, FLAT 77. HOSE, PUMP TO AUX CELL OUTLET (CURRENT
39. NUT, SELF LOCKING CONFIG)
40. NUT, PLAIN HEX 78. WASHER, FLAT (CURRENT CONFIG)
41. MODIFIED EXISTING VENT TUBE 79. PACKING, PREFORMED (CURRENT CONFIG)
42. BOLT, PAN HEAD, CLOSE TOLERANCE 80. CHECK VALVE (CURRENT CONFIG)
9. Supplemental Fuel Tank Foam Support B. Supplemental Fuel Tank Foam Support
Installation
A. Supplemental Fuel Tank Foam Support
Removal Consumable Materials
(Ref. CSPSPM)
(Ref. Figure 404) Item Nomenclature
(1). Remove fuel tank. C216 Sealant, Fuel Resistant
C721 Tape, Foam
NOTE: Foam support components are installed
with sealant or hook and loop tape. (Ref. Figure 404)
(2). Remove foam support as required by (1). If foam was installed with sealant,
pulling foam support loose from clean loose foam from attachment area
adjacent structure. to ensure a good bond.
Page 414
Sealant, Fuel Resistant (C216) (3). Install foam support as required using
hand pressure to ensure good attach
ment to adjacent structure.
(4). Use foam tape (C721) to hold in place
until sealant cures.
(2). If installing support foam with sealant (5). Remove tape.
(C216), apply sealant to foam in area of
attachment. (6). Install fuel tank.
10
8
9
9G28-072
1. FOAM SUPPORT, AFT, LH, OUTBOARD 6. FOAM SUPPORT, LOWER, RH

2. FOAM SUPPORT, AFT, LH, INBOARD 7. FOAM SUPPORT, LOWER, CENTER
3. FOAM SUPPORT, AFT, RH 8. FOAM SUPPORT, LOWER, SUMP
4. FOAM SUPPORT, FORWARD, RH 9. FOAM SUPPORT, LOWER, LH
5. FOAM SUPPORT, FORWARD 10. FOAM SUPPORT, FORWARD, LH
Figure 404. Supplemental Fuel Tank Foam Support Installation
10. Supplemental Fuel Transfer System (3). Remove center and aft cabin floor
panels (Ref. Section 53-20-00).
A. Supplemental Fuel Transfer System Aviation Turbine Fuel
Removal
(Ref. Figure 405)
(1). Defuel supplemental and main fuel (4). Remove fuel transfer hose (3).
tanks (Ref. Section 12-00-00).
(5). Remove fuel transfer elbow (4).
(2). Remove center baggage floor panel (6). Remove main fuel tank aft LH access
(Ref. Section 53-20-00). cover (Ref. Section 28-00-00).
Page 415
NOTE: Prior to removing all bolts (17) reach (2). Install new packing onto check valve.
under access cover and support the fuel level
Ensure flow arrow on check
control valve (13). CAUTION valve is facing down after instal
(7). Remove bolts (17) washers (18) and lation.
packings (19). (3). Install check valve into aft LH main
(8). Disconnect fuel transfer hose (10) from fuel tank vent/rollover valve mounting
elbow (9) and remove fuel level support plate. Torque check valve (Ref. CSP-
valve and attached parts. SPM).
(4). Lubricate new packing with aviation
(9). Remove check valve (6) from aft LH turbine fuel (C113).
main fuel tank vent/rollover valve
mounting plate. Remove packing (7) (5). Install nut onto bulkhead elbow and
and discard. install new packing onto elbow.
(10). Remove loosen jam nut (8) and remove (6). Install bulkhead elbow into check
bulkhead elbow(9) from check valve. valve. Torque jam nut (Ref. CSP-SPM).
Remove packing (7) and discard. (7). Attach fuel level control valve to
Remove jam nut. support bracket. Torque bolts (Ref.
(11). Disconnect fuel transfer hose (10) from CSP-SPM).
reducer (11). (8). Lubricate new packing with aviation
(12). Remove reducer (11) from fuel level
control valve (13). Remove and discard (9). Install new packing onto reducer and
packing (12). install reducer into fuel level control
valve. Torque reducer (Ref. CSP-SPM).
from fuel level control valve and remove (10). Using milli-ohm meter (T1002), test
valve from support bracket assembly. between reducer, level control valve,
and control valve support for a class S
B. Supplemental Fuel Transfer System electrical bond (Ref. CSP-SPM).
Installation Environmental seal is not required.
(Ref. Figure 405) (11). Attach fuel transfer hose to reducer.
Torque hose (Ref. CSP-SPM).
Consumable Materials (12). Place fuel level control valve support
(Ref. CSPSPM) and attached parts into main fuel tank.
Item Nomenclature (13). Attach fuel transfer hose to elbow at
C113 Fuel, Aviation Turbine check valve. Torque hose (Ref. CSP-
SPM).
(14). Support fuel level valve and position
Special Tools main fuel tank access cover over valve
(Ref. CSPSPM) support bracket. Install bolts, washers,
Item Nomenclature and packings. Torque bolts (Ref.
T1002 MilliOhm Meter CSP-SPM).
(15). Using milli-ohm meter (T1002), test
Aviation Turbine Fuel between access panel and control valve
support for a class S electrical bond
(Ref. CSP-SPM). Environmental seal is
not required.
(16). Align access cover attachment holes
(1). Lubricate new packing with aviation and install bolts and washers. Torque
turbine fuel (C113). bolts (Ref. CSP-SPM).
Page 416
(17). Install fuel transfer elbow into vent/rol (20). Attach transfer hose to supplemental
lover mounting plate. Torque elbow fuel tank fitting. Torque hose (Ref.
(Ref. CSP-SPM). CSP-SPM).
(18). Using milli-ohm meter (T1002), test (21). Install center and aft cabin floor panels
hose and elbow for a class S electrical (Ref. Section 53-20-00).
bond (Ref. CSP-SPM). Environmental (22). Install center baggage floor panel (Ref.
seal is not required. Section 53-20-00).
(19). Install fuel transfer hose onto elbow. (23). Perform main and supplemental fuel
Torque hose (Ref. CSP-SPM). tank leak check/pressure test.
4 (REF)
17 (4PL) 7 (REF)
18 (4PL) FS
19 (4PL) 230.500
6 (REF) 5 4
1 3
20
WL
104.400
16 11
12 6
14 (4PL) 7 (2PL)
15 (4PL)
10 8
2
13
9
9G28-066
1. MAIN FUEL TANK 12. PACKING, PREFORMED

2. SUPPLEMENTAL FUEL TANK 13. VALVE, LEVEL CONTROL, FUEL
3. HOSE, SUPPLEMENTAL TANK TO MAIN TANK 14. BOLT
4. ELBOW, FUEL TRANSFER 15. WASHER, FLAT.
5. VALVE, VENT/ROLLOVER, MAIN TANK 16. BRACKET ASSEMBLY, LEVEL CONTROL VALVE
6. CHECK VALVE SUPPORT
7. PACKING, PREFORMED 17. BOLT
8. JAM NUT 18. WASHER FLAT
9. ELBOW, FLARED TUBE, BULKHEAD 19. PACKING WITH RETAINER
10. HOSE, ELBOW TO LEVEL CONTROL VALVE 20. MAIN FUEL TANK COVER
11. REDUCER
Figure 405. Supplemental Fuel Transfer System Installation
Page 417
Page 418

INSPECTION/TEST
1. Supplemental Fuel System Inspection (5). Inspect fuel transfer hose for deteriora
tion, collapse, kinked, of loss of torque.
There is no definite minimum or maximum No damage allowed.
service life of the supplemental fuel system. The
best insurance for trouble-free service is the (6). Inspect fuel filler neck installation for
proper installation of the system. Periodic evidence of fuel leakage. Replace
inspection should be made to determine system components as required.
component failure or leakage. Aviation Turbine Fuel
A. Supplemental Fuel Tank Inspection
Fuselage External
(1). Inspect gravity fill port filler neck cap

for missing or damaged seal. CAUTION
(2). Inspect fuel vent fairing for damage. (7). Inspect fuel tank access cover for
Inspect for obstruction of air flow. evidence of fuel leakage, electrical
Repair or replace as required. bonding jumper for corrosion and
security. Repair as required.
(3). Inspect the exterior of fuselage beneath
the fuel cell for indications of fuel (8). Inspect fuel vent tubes for cracks, dents,
leakage. No leaks allowed. Repair or nicks and corrosion. Hoses for cracks,
replace components as required. cuts, tears, punctures, and collapse. No
damage allowed. Inspect clamps and
B. Supplemental Fuel Tank Inspection attaching hardware for security. Repair
Fuselage Internal or replace as required.
NOTE: (9). Inspect aft standpipe vent tubes,

attaching hardware, and flame arrestor
Perform Supplemental Fuel Tank Leak for cracks, dents, nicks and corrosion.
Check/Pressure Test to determine if leaks Inspect hoses for cracks, cuts, tears,
exist in the fuel system. If the pressure punctures, and collapse. No damage
test does not indicate leakage, a visual in allowed. Repair or replace as required.
spection is not required.
(10). Remove fuel tank access cover.
Perform fuel tank inspection - internal
fuselage when floor panels are removed (11). Inspect fuel vent float/rollover valve and
for other maintenance. hardware for serviceable condition,
leakage, and corrosion. No damage
(1). Defuel supplemental fuel tank (Ref. allowed. Repair or replace as required.
Section 12-00-00).
(12). Inspect electrical bonding jumpers,
(2). Remove baggage compartment center hardware, and clamps for corrosion,
floor A235 and right outboard panel damage, and security. No damage
R250 (Ref. Section 53-20-00). allowed. Repair or replace as required.
(13). Inspect fuel transfer hose for deteriora
(3). Remove cabin floor LH aft access cover tion, collapsed, kinked, or loss of torque.
AL230 (Ref. Section 53-20-00). No damage allowed.
(4). Inspect elbow fitting at main fuel tank (14). Inspect fuel transfer pump and attach
vent/rollover valve mounting plate for ing hardware for condition and security.
evidence of leakage. None allowed. Repair or replace as required.
Page 601
28-10-00 Revision 1
(15). Inspect fuel quantity transmitter for D. Supplemental Fuel Cavity Inspection
condition and security. Repair or
replace as required. Aviation Turbine Fuel
(16). Install fuel tank access cover.
(17). Perform supplemental fuel tank leak
check/pressure test.
(18). Fuel helicopter as required (Ref. (1). Remove supplemental fuel tank.
Section 12-00-00).
(2). Remove supplemental fuel tank support
C. Supplemental Fuel Transfer Inspection foam.
NOTE: (3). Inspect supplemental fuel tank and
Perform Supplemental Fuel Tank Transfer filler neck installation cavity for:
Operational Test to determine if transfer
components are operating correctly. If the (a). Ensure openings through boattail tub
transfer test does not indicate improper op skin are clear and open.
eration, a visual inspection is not required.
(b). Ensure all openings to adjacent areas
Perform fuel transfer inspection when floor
are sealed with tape and sealant to
panels are removed for other maintenance.
provide a fuel and fuel vapor tight
(1). Defuel main fuel tank (Ref. Section barrier. No openings allowed to
12-00-00). adjacent areas. Repair or replace as
required.
(c). Inspect support foam for condition
and security. Repair or replace as
required.
(2). Perform Supplemental Fuel Tank 1). Support foam maximum allowable
Inspection - Fuselage Internal. irregularities of 0.060 in. (1.52
mm) in depth, within 0.50 in.
(3). Remove cabin floor panels A170 and (12.7 mm) of part edges.
A217 (Ref. Section 53-20-00).
2). Other surfaces maximum allow
System Contamination able irregularities of 0.125 in (3.18
CAUTION
mm) in depth.
(4). Remove aft LH main fuel tank access
cover (Ref. Section 28-00-00). 3). Inspect condition of fuel tank
attaching hook or loop tape. Repair
(5). Inspect fuel transfer components for or replace as required.
condition and security. Repair and
replace as required. (d). Inspect fuel tank sump support for
(6). Install aft LH main fuel tank access
cover (Ref. Section 28-00-00). (e). Ensure drain hole in fuel filler neck
compartment is clear and open.
(7). Install cabin floor panels A170 and
A217 (Ref. Section 53-20-00). (4). Install fuel tank support foam.
(8). Perform Fuel Cell Leak Check/Pressure
Test (Ref. Section 28-00-00). (5). Install supplemental fuel tank.
(9). Fuel helicopter as required (Ref. (6). Perform Supplemental Fuel Tank Leak
Section 12-00-00). Check/Pressure Test.
Page 602
Revision 1 28-10-00
2. Supplemental Fuel Tank Leak (8). Connect the air supply and U-tube
Check/Pressure Test manometer (T2014-4) hose to the fuel
transfer hose (2).
A. Supplemental Fuel Tank Leak
Check/Pressure Test Method 1 (Requires (9). Use clean, regulated, low pressure,
Floor Panel Removal) filtered, compressed air source, an
accurate pressure gage and a shut-off
(Ref. Figure 601) valve.
Ensure baggage floor is
CAUTION installed with a minimum of ev
(Ref. CSPSPM) ery other screw.
Item Nomenclature (10). Ensure supplemental fuel filler cap is
C702 Lockwire tightly secured.
C809 Leak Detector, Liquid (11). If new fuel cell is installed, slowly apply
2.0 psig (13.8 kPa) using air pressure
regulator (T2014-6), 56 inches of
Special Tools water as measured on the manometer
(Ref. CSPSPM) (T2014-4) to the hose and hold for 10
Item Nomenclature minutes as a precautionary measure.
This will allow air trapped between the
T20144 Manometer cell and the helicopter structure to
T20146 Regulator, Air Pressure escape and also allow the cell to adjust
to the contour of the cell cavity. Release
the air pressure slowly and repeat if
(1). Defuel supplemental fuel tank (Ref. necessary.
Section 12-00-00).
(12). Slowly apply 2.0 psig (13.8 kPa) of
(2). Remove baggage compartment floor regulated air pressure to obtain 56
(Ref. Section 53-20-00). inches of water to the fuel cell as
measured on the manometer
Aviation Turbine Fuel (T2014-4).
(13). After the air supply pressure is shut off,
verify that the air pressure inside does
not drop more than 0.125 psig (0.86
kPa) or 3.5 inches of water after 15
(3). Remove lockwire (2) and slide hose (1) minutes as measured on the manomet
to expose end of vent tube (3). er (T2014-4).
Do not attempt to remove
NOTE: Cap must be capable of retaining 2.0 WARNING access panels with air pres
psig (13.8 kPa). sure applied. This could result in seri
ous injury and damage to fuselage
(4). Cap end of vent tube (3). structure.
(5). Install baggage compartment floor with (14). If leakage exceeds the amount allow
a minimum of every other fastener (Ref. able, apply liquid leak detector (C809)
Section 53-20-00). to areas suspected of leaking.
(6). Remove aft left main fuel tank vent/rol (15). Test fuel drain plug.
lover valve access panel AL230 (Ref. (16). Slowly release air pressure from fuel
Section 53-20-00). cell.
(7). Disconnect fuel transfer hose (2) from (17). Remove baggage area floor panels and
elbow fitting (1). check all connections.
Page 603
28-10-00 Revision 1
(18). Reinstall panels and retest. (21). Reconnect fuel transfer hose to elbow
fitting. Torque fitting (Ref. CSP-SPM).
(19). If test is successful, slowly release air
pressure from fuel cell, disconnect the
(22). Reinstall aft left main fuel tank
air supply and U-tube manometer
vent/rollover valve access panel AL230
(T2014-4) hose from the fuel transfer
hose.
(20). Reconnect vent hose to vent tube and (23). Reinstall baggage floor panels (Ref.
secure with lockwire (C702). Section 53-20-00).
FS
235.532
2 (2PL) 3
1
BL
0.00
9G28-075
1. VENT HOSE 3. VENT TUBE

2. LOCKWIRE
Figure 601. Supplemental Fuel Tank Leak/Pressure Test Method 1 (Sheet 1 of 2)
Page 604
Revision 1 28-10-00
FS
230.50
1 2
9G28-076
1. ELBOW FUEL TRANSFER 2. HOSE FUEL TRANSFER
Figure 601. Supplemental Fuel Tank Leak/Pressure Test Method 1 (Sheet 2 of 2)

B. Supplemental Fuel Tank Leak NOTE: Using the Test Method 2 tests both
Check/Pressure Test Method 2 (Does Not the main and supplemental fuel tanks si
Require Floor Removal) multaneously.
(2). Perform Fuel Cell Leak Check/Pressure
Consumable Materials Test Test Method 2 for main fuel tank
(Ref. CSPSPM) (Ref. Section 28-00-00).
Item Nomenclature (3). If leakage exceeds the amount allow
C809 Leak Detector, Liquid able, apply liquid leak detector (C809)
to areas suspected of leaking.
(4). Test most accessible areas first (Ref.
Special Tools
Fuel Cell Leak Check/Pressure Test,
Section 28-00-00).
(Ref. CSPSPM)
Item Nomenclature (5). Test supplemental fuel tank drain plug.
T20144 Manometer (6). Slowly release air pressure from fuel
T20146 Regulator, Air Pressure cell.
(7). Remove baggage area floor panels and
check all connections.
(1). Ensure supplemental fuel filler cap is
tightly secured. (8). Reinstall panels and retest.
Page 605
28-10-00 Revision 1
3. Supplemental Fuel Quantity Operational (2). Fill the supplemental fuel tank full
Test (Ref. Section 12-00-00)
(Ref. Figure 602) (3). Verify the IIDS and FUEL PROBE
circuit breakers on the A601 essential
(1). Defuel supplemental fuel tank (Ref circuit breaker panel are in (Ref.
Section 12-00-00). Section 96-00-00).
(2). Place helicopter in normal ground (4). Verify the AUX FUEL XMIT and AUX
attitude of 3 degrees nose up (Ref. FUEL circuit breaker on the A620
Section 08-20-00). electrical load center is in (Ref. Section
96-00-00).
(3). Verify the AUX FUEL XMIT circuit
(5). Apply electrical power to the aircraft
breaker on the A620 electrical load (Ref. Section 96-00-00).
center is in (Ref. Section 96-00-00).
(6). Place supplemental fuel transfer switch
(4). Apply electrical power to the aircraft (2) in the ON position.
(7). Verify pump indicator light (1) illumi
(5). Verify supplemental fuel quantity nates and transfer pump is operating
indicator (3) indicates EMPTY. audibly.
(6). Verify supplemental fuel quantity (8). Transfer of fuel shall stop once 34 lb
indicates from EMPTY to FULL as (15 kg)(5 U.S. gal (18.9 L)) to 170 lb
supplemental fuel tank is filled (Ref. (77 kg)(25 U.S. gal (94.6 L)) of fuel
Section 12-00-00). has been transferred.
(7). Remove power from aircraft (Ref. NOTE: Fuel transfer has stopped when the
Section 96-00-00). main and supplemental fuel quantity indi
cators have stabilized and possibly an audi
ble change in transfer pump sound.
4. Supplemental Fuel Transfer Operational
Test (9). Continue to run transfer pump for 10
minutes and verify no change in fuel
(Ref. Figure 602) quantity indication for main or supple
mental fuel tank.
(1). Service main fuel tank to approximate
ly 564 lb (256 kg) (83 U.S. gal (314 (10). Remove power from aircraft (Ref.
L)) (Ref. Section 12-00-00). Section 96-00-00).
Page 606
1
2
3 (NOTE)
AUXILIARY FUEL SYSTEM

USE MAIN FUEL DOWN TO
700 LBS BEFORE SELECTING
AUX FUEL TRANSFER. DO NOT
USE AUX FUEL TRANSFER BELOW
MAIN FUEL OF 300 LBS.
NOTE: GAUGE MAY BE INSTALLED ANYWHERE WITHIN SIGHT OF THE PILOT.
9G28-070
1. FUEL TRANSFER INDICATOR LIGHT 3. SUPPLEMENTAL FUEL QUANTITY INDICATOR
2. FUEL TRANSFER SWITCH
Figure 602. Supplemental Fuel Transfer Operational Test

28-10-00 Revision 1

MODIFICATION/REPAIR
1. Main Fuel Tank Cover Modification (1). Using referenced figure, locate holes in
access cover.
(Ref. Figure 801)
(2). Drill holes with a number forty (40) (2.5
The LH aft main fuel cell access cover has mm) pilot drill.
been modified on helicopters with the supple
mental fuel system installed. These modified (3). Enlarge holes in access cover to 0.281
access covers do not have a different part " 0.010 in. (7.14 " 0.25 mm) and
number than a non-modified cover. For a deburr holes.
replacement it is necessary to order a standard
access cover and modify it. The modification (4). Touch up holes in accordance with
consists of drilling four (4) holes for mounting Aluminum Alloy Surface Touch-up
the level control valve support. Treatment (Ref. CSP-SPM).
5.25 IN
1.50 IN (13.34 cm)
(3.81 cm)
1.40 IN
(3.56 cm)
5.19 IN
(13.18 cm)
4X O 0.281 +/- 0.010 (7.14 mm +/- 0.25 mm)
9G28-068
Figure 801. Main Fuel Tank Cover Modification
Page 801
28-10-00 Revision 1
2. Aft Vent Tube Modification
(Ref. Figure 802)
The aft vent tube has been modified on

helicopters with the supplemental fuel system
installed. These modified vent tubes do not
have a different part number than a non-mo
dified vent tube. For a replacement it is
necessary to order a standard vent tube part
number 900P2662013 and modify it. The
modification consists of trimming the vent
tube and touch up of bare aluminum.
(1). Remove vent tube (Ref. Section

28-00-00).
(2). Mark vent tube for modification in 6.16 IN

accordance with referenced figure. (15.65 cm)
(3). Cut vent tube at mark and deburr.

9B28-071
(4). Touch up bare aluminum (Ref. CSP-
SPM). Figure 802. Aft Vent Tube Modification
Page 802
Revision 1 28-10-00
3. Right Outboard Baggage Floor Panel

Modification
(Ref. Figure 803)
The right outboard baggage floor panel has 4

been modified on helicopters with the supple
mental fuel system installed. These modified
panels do not have a different part number
than a non-modified panel. For a replacement
it is necessary to order a standard panel part
number 900F2305507 and modify it. The
modification consists of trimming the panel,
touch up of bare aluminum, riveting two
doublers along the cutout, and installing
nutplates.
2
(1). Mark panel using old panel or new
doublers. 3
(2). Trim panel using aviation metal snips.
(3). Deburr and blend edges.
(4). Locate doublers along edge of cutout.
1
(5). Drill doubler and nutplate rivet holes
and deburr. 9G28-077
1. MODIFIED RIGHT OUTBOARD BAGGAGE FLOOR
PANEL
(6). Touch up bare aluminum (Ref. CSP- 2. UPPER OUTBOARD DOUBLER
3. UPPER INBOARD DOUBLER
SPM). 4. LOWER PANEL DOUBLER
Figure 803. Right Outboard Baggage Floor

(7). Install doublers and nutplates. Panel Modification
Page 803
28-10-00 Revision 1
4. Supplemental Fuel Tank Support Foam component protrusion with foam tape
Repair (C718).
(6). Build up thickness of tape to allow
Consumable Materials approximately 30 percent compression
(Ref. CSPSPM) after fuel tank installation.
Item Nomenclature
C216 Sealant, Fuel Resistant 5. Supplemental Fuel Tank Cavity Vapor
C310 Primer
Barrier Repair
C505 Foam, Rigid, Structural, Closed Cell Consumable Materials
(Ref. CSPSPM)
C720 Tape, Fastener, Hook & Loop
Item Nomenclature
C718 Tape, Foam
C719 Tape, Aluminum
Sealant, Fuel Resistant (C216)
(1). Replace unserviceable aluminum tape

(C719) with new and seal edges with
sealant (C216).
(1). Small irregularities of less than 1.00
(2). Seal small holes in cavity vapor barrier
cubic in. (2.54 cubic cm) may be filled
with sealant (C216).
with sealant (C216) or epoxy adhesive
(C411). 6. Fuel Neck Cover Seal Replacement
Foam, Rigid, Structural (C505)
(Ref. CSPSPM)
Item Nomenclature
(2). Large irregularities, including entire C718 Tape, Foam
foam block fabrication, may be filled
with new rigid foam (C505) material
and bonded in place with epoxy adhes (1). Remove fuel neck cover.
ive (C411). or sealant (C216). (2). Remove unserviceable seal.
Primer (C310) Solvent Cleaner (C429)
(3). Surface seal all foam repairs with (3). Clean surface with solvent cleaner
primer (C310). (C429) and allow to air dry a minimum
of 15 minutes.
(4). Rebond loose hook & loop tape (C720)
with sealant (C216). (4). Install new foam tape (C718) along
outboard flange of fuel neck cover.
(5). Fill all areas where foam supports are
unsupported due to structural and (5). Install fuel neck cover.
Page 804
Revision 1 28-10-00
7. Supplemental Fuel Check Valve (6). Remove bolts (12) and washers (13).
Modification Remove fuel tank cover (7). Remove
and discard packing (8).
A check valve may be installed inside the
supplemental fuel tank to prevent fuel from (7). Disconnect and remove existing pump
flowing from the supplemental fuel tank to the to auxiliary cell outlet hose.
main fuel tank when the transfer pump is not
on. (8). Remove nut (16) and washer (15) from
bulkhead tube fitting.
Consumable Materials (9). Install washer (14), four washers (15)
(Ref. CSPSPM) and nut (16) on bulkhead tube fitting.
Item Nomenclature Torque nut (Ref. CSP-SPM).
C702 Lockwire Upon installation of check
C113 Fuel, Aviation Turbine CAUTION valve, insure arrow on valve
points in direction of fuel flow in system.
Special Tools
(Ref. CSPSPM)
Item Nomenclature (10). Install check valve (17) on bulkhead
T1002 MilliOhm Meter tube fitting with new packings (19).
Torque check valve (Ref. CSP-SPM).
(Ref. Figure 804) (11). Using milli-ohm meter (T1002), test
check valve for a class S electrical bond
(1). Defuel supplemental fuel tank (Ref. (Ref. CSP-SPM).
Section 12-00-00).
(12). Attach new pump to auxiliary cell
(2). Remove baggage compartment floor outlet hose (18) to check valve and
(Ref. Section 53-20-00). pump fitting. Torque hose (Ref. CSP-
(3). Remove bolts (1), washers (2), bolts (3), SPM).
and washers (4) and remove hat (13). Install new packing (8) into groove on
support channel (5). top of fuel tank and install cover with
(4). Disconnect electrical connector (6) from bolts (12) and washers (13). Torque
top of fuel tank cover (7). bolts (Ref. CSP-SPM).
Aviation Turbine Fuel (14). Slide vent hose (10) to equally cover
gap between vent tubes (11) and install
lockwire (C702) (Ref. CSP-SPM).
(15). Connect electrical connector (6) to
transfer pump connector on top of fuel
(5). Remove lockwire (9) and slide hose (10) tank cover (7).
to expose end of vent tube (11).
(16). Install support hat channel (5) with
NOTE: Use care when removing fuel tank cov bolts (3), washers (4), bolts (1), and
er, transfer pump wire harness has approxi washers (2). Torque bolts (Ref. CSP-
mately 10 in. (25.4 cm) of excess length. SPM).
Page 805
1
2
RH KEEL BEAM REF
TRANSFER PUMP REF SUPPLEMENTAL

FUEL TANK REF
FS
235.532
10 (2PL)
7 18
8
11
17
12 19
13
BL
0.000
16
9 (4PL) SUPPLEMENTAL 15
FUEL TANK
3 (4PL) FS
4 (4PL) 230.500
6 BULKHEAD 14
TUBE
FITTING REF
9G28-079
Figure 804. Supplemental Fuel Check Valve Modification
Page 806

1. BOLT, CLOSE TOLERANCE 11. TUBE ASSEMBLY, FUEL VENT
2. WASHER 12. BOLT, HEX HEAD, CLOSE TOLERANCE
3. BOLT, HEX HEAD, CLOSE TOLERANCE 13. WASHER, FLAT
4. WASHER, FLAT 14. WASHER, FLAT
5. CHANNEL, HAT SUPPORT 15. WASHER, FLAT (4)
6. CONNECTOR, FUEL TRANSFER PUMP 16. NUT, TUBE, BULKHEAD FITTING
7. COVER, SUPPLEMENTAL FUEL TANK 17. CHECK, VALVE
8. PACKING 18. HOSE, PUMP TO AUX CELL OUTLET
9. LOCKWIRE 19. PACKING PREFORMED
10. HOSE, CONNECTION, FUEL VENT
(17). Install baggage floor (Ref. Section (19). Perform supplemental fuel quantity
53-20-00). operational test.
(18). Perform supplemental fuel tank (20). Service fuel tank as required (Ref.
leak/pressure test. Section 12-00-00).
Page 807
Page 808
Chapter
HYDRAULIC SYSTEM
TABLE OF CONTENTS
29-00-00 Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A

1. Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Hydraulic Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
A. Variable Delivery Pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
B. Manifold/Reservoir Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
C. Distribution System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
D. GSE Panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Figure 1. Hydraulic System Block Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Figure 2. Hydraulic System Component/Subcomponent Locations . . . . . . . . . . . . 4
E. Hand Pump (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Figure 3. Hydraulic Hand Pump (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Fault Isolation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
1. Hydraulic System Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Table 101. Hydraulic System Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Figure 101. Hydraulic System 1 Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
Figure 102. Hydraulic System 2 Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
1. Hydraulic System Inspection/Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
A. Hydraulic System Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
B. Hydraulic System Pressure Leak Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
C. Hydraulic System Static Leak Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
D. Hydraulic System Operational Test (Aircraft Ground Run) . . . . . . . . . . . . . . . . . . 202
E. Hydraulic System Functional Test (with GSE Pressure). . . . . . . . . . . . . . . . . . . . . 202
Figure 201. Hydraulic Systems 1 and 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
2. Hydraulic System Pressure Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
A. External Hydraulic Pressure Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
3. Hydraulic Ground Support Equipment (GSE) Panel . . . . . . . . . . . . . . . . . . . . . . . . . . 205
A. Hydraulic GSE Panel Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
B. Hydraulic GSE Panel Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
C. Hydraulic GSE Panel Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
Figure 202. Hydraulic Ground Support Equipment (GSE) Panel . . . . . . . . . . . . . 206
4. Hydraulic Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
A. Hydraulic Pump Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
B. Hydraulic Pump Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
C. Hydraulic Pump Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
Page i

Figure 203. Hydraulic Pump Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . . . 208
5. Hydraulic Manifold/Reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209
A. Hydraulic Manifold/Reservoir Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209
B. Hydraulic Manifold/Reservoir Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209
C. Hydraulic Manifold/Reservoir Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210
6. Hydraulic Manifold/Reservoir Filter and Bowl Assembly . . . . . . . . . . . . . . . . . . . . . . 211
A. Hydraulic Manifold/Reservoir Filter and Bowl Assembly Removal . . . . . . . . . . . 211
B. Hydraulic Manifold/Reservoir Filter and Bowl Assembly Installation . . . . . . . . . 211
7. Hydraulic Pressure Transducer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212
A. Hydraulic Pressure Transducer Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212
B. Hydraulic Pressure Transducer Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212
C. Hydraulic Pressure Transducer Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212
8. Hydraulic Temperature Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213
A. Hydraulic Temperature Switch Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213
B. Hydraulic Temperature Switch Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213
C. Hydraulic Temperature Switch Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213
Figure 204. Hydraulic Manifold/Reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214
9. Manifold Filter Bypass (Delta P) Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215
A. Reset Bypass (Delta P) Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215
B. Bypass (Delta P) Indicator Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215
C. Bypass (Delta P) Indicator Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215
D. Bypass (Delta P) Indicator Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215
10. Hydraulic Bleed Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216
A. Hydraulic Bleed Valve Packing Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216
11. Hydraulic System Select Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216
A. Hydraulic System Select Solenoid Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216
B. Hydraulic System Select Solenoid Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217
Figure 205. Hydraulic Manifold/Reservoir Component Replacement . . . . . . . . . . 218
12. Hydraulic Hand Pump (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219
A. Hydraulic Hand Pump Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219
B. Hydraulic Hand Pump Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219
C. Hydraulic Hand Pump Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219
Figure 206. Hydraulic Hand Pump (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220
Page ii
Section
290000
Hydraulic System
HYDRAULIC SYSTEM
1. Hydraulic System ing system's pressure decreases to between
200 psig and 400 psig.
(Ref. Figure 1)
Fluid is carried through drilled passages to the
The hydraulic control system is a dual circuit contact face of each piston shoe for lubrication,
system. The system supplies pressure to three cooling, and hydrostatic balance. This hydro
dual circuit servoactuators to assist main rotor static balance reduces bearing contact
flight controls operation. System 2 also pressures, minimizing friction and wear. Other
supplies pressure to a single circuit servoac parts are lubricated and cooled with this fluid
tuator to assist anti-torque/directional flight as it circulates at 0.02 to 0.08 gpm through the
controls operation. The hydraulic system uses pump and returns to the manifold/reservoir.
hydraulic fluid (C112) that is approved for B. Manifold/Reservoir Assemblies
operations in temperatures between -40 F to
+275 F. Servicing is accomplished by using The manifold/reservoir assembly distributes
ground support equipment, or the optional the pressurized hydraulic fluid to the servoac
hand pump. tuators. The manifold/reservoir assembly is
the collection point for the fluid returns, and
Systems 1 and 2 operate nominally at 500 contains the system operating fluid. The
psig. If pressure is lost in one of the hydraulic manifold/reservoir assembly components are
systems, the remaining system pump output mounted in an aluminum alloy housing. All
pressure increases to 1000 psig. Each circuit fluid connection fittings on the manifold/reser
consists of the following components: voir are of the ring-lock type.
The bootstrap reservoir prevents cavitation
2. Hydraulic Components during high system flow demands. It main
tains a 2.4 psig minimum static pressure to
(Ref. Figure 2) the pump when the system is shut down and
27 psig during normal system operation.
A. Variable Delivery Pumps
The reservoir bleed valve provides for removal
The two hydraulic pumps are piston type of entrapped air and prevents the reservoir
variable displacement pumps capable of from being over pressurized above 150 psig.
providing flow rates up to 2.2 gpm. Each pump The valve is a spring-loaded valve used to
is driven by an accessory drive on the main bleed the system during servicing. The valve is
transmission. The pump drive shaft is coupled mounted in the housing assembly at the
to the transmission accessory drive by a spline highest point. CURRENT CONFIG - The
which will shear in the event of a physical bleed valve is also used for obtaining fluid
overload. samples.
A system relief valve prevents damage to the
Each pump contains nine pistons arranged hydraulic system in the event the pressure
axially in a floating cylinder block. A compen compensator in the pump malfunctions. The
sator circuit varies pump displacement to valve actuates at 1350 psig and resets at a
maintain a constant 500 psig during varying minimum pressure of 1150 psig.
system flow requirements, providing rapid
pump response. Mechanical stops at full flow The pressure and return filters are standard
and full cut off positions prevent system five micron filter elements contained in
damage. threaded filter bowls. When the filter bowl
assembly is removed a shutoff valve closes,
If pressure is lost in one of the hydraulic isolating the system fluid to prevent leakage.
systems, the functioning system's pump A set of spring-loaded levers prevent the filter
compensator circuit is reset to 1000 psig. The bowl from being installed without the filter
compensator is reset when the mis-function element.
Page 1
The Delta P indicator indicates when the filter EARLY CONFIG - The fluid sampling valve
is to be replaced. A pressure drop across the provides for fluid samples to be taken while
dirty filter displaces a piston inside the the system is fully pressurized. The valve
indicator releasing the center pop-up. A nozzle is fitted with a protective cap attached
thermal lockout prevents a false indication to a security chain.
during low fluid temperature conditions. The
indicator can only be reset after removing the The quantity indicator provides visual
dirty filter. indication of reservoir fluid quantity. The
indicator has individual FULL and REFILL
marks for fluid level at hot and cold fluid
The return filter bypass valve provides a temperatures.
bypass around the filter if the pressure drop
across the filter becomes excessive. It is a The GSE isolation valve in the GSE return
spring-loaded poppet type relief valve. port of the manifold separates the GSE return
lines from the hydraulic system. It is a
spring-loaded poppet valve which opens when
The pressure transducer is a strain gauge, 200 psig is applied to the GSE pressure port
bridge type transducer which converts psig to and resets at a minimum pressure of 80 psig.
an electrical signal for cockpit indications.
During a system pressure loss the HYD 1/2 C. Distribution System
light illuminates on the IIDS and the system
pressures are displayed on the fault line. Stainless steel tubing is used for hydraulic
fluid distribution to reduce corrosion and
damage. Permaswedge fittings help to
The high temperature switch is installed in minimize the possibility of leakage by reducing
the return line to the reservoir. The switch the number of threaded connectors. Clamp
comes on at approximately 235 F, and off at blocks provide spacing of 0.25 in (6.35 mm) for
approximately 205 F. An overheat condition is the tubing to prevent chafing.
displayed on the IIDS.
Hydraulic hoses are installed at the actuators
to allow freedom of movement during opera
The system pressure check valve prevents tion. The hoses are sleeved for fire protection
reverse flow of hydraulic fluid within the and all threaded fittings are safety wired.
manifold. The check valve is a removable
cartridge type check valve and is integrated D. GSE Panels
into a fitting within the manifold.
The GSE panel is located on the left side of the
main transmission deck. The panel provides
The system solenoid valve simulates loss of quick disconnect for ground servicing equip
system pressure for pump compensator ment. The panel has a pressure and return
functional checks. When open, the valve short line connected to the manifold/reservoir. The
circuits supply pressure to return, reducing GSE panel is isolated from the hydraulic
system pressure to approximately 200 psig. system when not in use.
Page 2
SYSTEM 1 HAND SYSTEM 2

PUMP
(OPTIONAL)
VARIABLE VARIABLE
DELIVERY DELIVERY
PUMP PUMP
GSE MANIFOLD MANIFOLD GSE

PANEL RESERVOIR RESERVOIR PANEL
COLLECTIVE SERVO ACTUATOR
LONGITUDINAL SERVO ACTUATOR
LATERAL SERVO ACTUATOR
DIRECTIONAL SERVO ACTUATOR
9G29-005A
Figure 1. Hydraulic System Block Diagram
Page 3
SYSTEM NO. 2 PUMP
DELTA PRESSURE INDICATORS

(FILTER IMPENDING BYPASS) SYSTEM NO. 1 PUMP
GSE PANELS
SAMPLING
PRESSURE VALVE
TRANSDUCER
FLUID TEMP
-40C 95C
F
F U
U L
L L
L
FLUID LEVEL R
SIGHT GAUGE R E
E F
SYSTEM SELECT F I
EARLY CONFIG I L
SOLENOID
L L
L EMPTY
LOOKING INBOARD
CURRENT CONFIG
RETURN FILTER
BY-PASS VALVE
HIGH PRESSURE
RELIEF VALVE
BLEED VALVE
ISOLATION FLUID TEMP
VALVE -40C 95C
FULL
TEMPERATURE
SWITCH FULL
REFILL
REFILL
EMPTY
FILTER BOWL
(PRESSURE) VIEW ROTATED
FILTER BOWL LOOKING DOWN
(RETURN) 9G29-003B
Figure 2. Hydraulic System Component/Subcomponent Locations
Page 4
E. Hand Pump (Optional) The pump assembly consists of two pumping

gears and the speed increasing gear located in
(Ref. Figure 3) a housing. The pump housing also contains the
The hand pump provides the capability to reservoir drain.
pump fluid into the manifold/reservoir without
the need of a ground support unit. The hand A manually operated selector valve is mounted
pump is mounted next to the GSE panels on internally in the housing. The selector valve
the transmission deck. The hand pump outlet lever provides for selection of system 1 or
ports connect to the GSE return lines. system 2 for servicing.
The reservoir and cover consists of a sheet
metal housing bolted to the main pump The outlet ports incorporate an adapter with
housing. Elastomeric check valves allow air to an integral check valve. The check valve
enter the reservoir when fluid is pumped out prevents reverse flow of hydraulic fluid from
and prevent pressurization of the reservoir due the GSE return lines connected to the reser
to heating. A sight glass indicates when the voir/manifold. The adapter is a ring locked
fluid is at the 0.3 qt level. The cover has a can type flareless tube fitting.
opener on it's underside for opening cans of
hydraulic fluid. A 100 micron wire screen The drive handle folds and clips against the
covers the bottom of the reservoir and can be reservoir housing for storage. When in use the
removed for cleaning. handle is locked in place by a sliding sleeve.
HANDLE IN
STOWED POSITION
FLUID LEVEL
INDICATOR
SYS #1
OUTLET PORT
SYS #2
OUTLET PORT
HANDLE IN
SELECTOR VALVE OPERATING POSITION
LEVER
9G29-008
Figure 3. Hydraulic Hand Pump (Optional)
Page 5
Page 6
HYDRAULIC SYSTEM
FAULT ISOLATION
1. Hydraulic System Troubleshooting Troubleshooting tables should be used with
(Ref. Figure 101 and Figure 102) procedures in this and other chapters of the
manual.
brief summary of hydraulic system faults, in the Rotorcraft Maintenance Manual
Table 101. Hydraulic System Troubleshooting

1 HYD and HYD 2 not Faulty K17/8 AOG relay. Replace relay K17/8. 963000
present on IIDS during
System 1 and System 2 self 28 vdc not present at Test and repair wiring. 980000
test. K17/8B2.
CB 48 inoperative. Replace circuit breaker. 963000
Faulty switch S5 A606 Utility Replace switch. 963000
Control Panel.
1 HYD not present on IIDS Open ground between Test and repair wiring. 980000
during System 1 self test. GS107J and P429B.
Faulty test solenoid. Replace solenoid.
28 vdc not present at Test and repair wiring. 980000
K17/8B2.
CB 48 inoperative. Replace circuit breaker. 963000
Control Panel.
1 HYD present on IIDS Faulty pressure transducer Replace transducer. 963000

during System 1 self test, but on A400 hydraulic manifold
no pressure reading below 1.
250psi present on alpha
numeric IIDS display.(With no Faulty wiring between A400 Test and repair wiring. 980000
IIDS SENSEFALT BIT 15 hydraulic manifold 1 P428
=7.5V EXCITATION failure.) and A2 IIDS P102.
1 HYD present on IIDS and Faulty pump. Internally Test pump output pressure with 290000
low pressure reading present worn. mechanical gauge and repair or
on alpha numeric display. replace pump as necessary.
Loose / broken fitting or Repair/replace fitting/line. 290000
cracked/broken line.
Leaking actuator. Repair/replace actuator. 671000
Page 101
29-00-00 Original
Table 101. Hydraulic System Troubleshooting (Cont.)

HYD 2 not present on IIDS Open ground between Test and repair wiring. 980000
during System 2 self test. GS107B and P425B.
Faulty test solenoid. Replace solenoid.
28Vdc not present at Test and repair wiring. 980000
K17/8B2.
C.B. 48 inoperative. Replace circuit breaker. 963000
Control Panel.
HYD 2 present on IIDS Faulty pressure transducer Replace transducer. 290000
during System 1 self test, but on A401 manifold 1.
no pressure reading below
250psi present on alpha Faulty wiring between A401 Test and repair wiring. 980000
numeric IIDS display. (With hydraulic manifold 2 P423
no IIDS SENSEFALT BIT 15 and A2 IIDS P103.
=7.5V EXCITATION failure.)
HYD 2 present on IIDS and Faulty pump. Internally Test pump output pressure with 290000
low pressure reading present worn. mechanical gauge and repair or
on alpha numeric display. replace pump as necessary.
Loose / broken fitting or Repair/replace fitting/line. 290000
cracked/broken line.
Leaking actuator. Repair/replace actuator. 671000
Hydraulic System 1 or 2 filter Filter is dirty. Replace hydaulic filter and 290000
impending bypass delta reset bypass (delta P) indicator.
pressure indicator will not
reset. Bypass (delta P) indicator Remove and clean bypass 290000
(NOTE: dirty. (delta P) indicator.
Filter bowl must be removed Faulty bypass (delta P) Replace bypass (delta P) 290000
to allow button to be reset) indicator. indicator.
Page 102
A606
W124 A612 A400

S5 FWD INTERCONNECT PANEL MANIFOLD/
HYD TEST SWITCH J1 P117 W123 W129 RESERVOIR 1
P172 J6 J1 P171 J155 P155 P429 J3
3 SYS 1
2 L 84 83 N A SYS SELECT
OFF E P B SOLENOID
M 85 86 GS107-J
1 SYS 2
W123 P427 J1
J157 P157
86
K1-7/8 28 B TEMP SWITCH
N
AOG RELAY 27 A
B3
P428 J2
Q Q
B1 B2 Q
29 A
A620 30 B
ELECTRICAL LOAD CENTER A3 PRESS XDCR
W124 31 C
A1 A2 32 D
CB48 J2 P374
CFU 7
5A 37 6 X1 X2 6
HYD TEST
8 6 SEE ELECTRICAL INTERCONNECT
RIGHT DIAGRAM 98-40-00
GENERATOR
7 900 CONFIG
BUS
87
8 902 CONFIG
A2
IIDS
W123
J4 P104
GS105-E E
HYD OIL TEMP 1 HI R
J2 P102 W123
Q
HYD OIL PRESS 1 EXCIT HI 15
HYD OIL PRESS 1 EXCIT LO 16
HYD OIL PRESS HI 17
HYD OIL PRESS LO 18
9G29-004-1B
Figure 101. Hydraulic System 1 Wiring Diagram
Page 103
29-00-00 Original
A606
A612
S5 W124 FWD INTERCONNECT PANEL W123 W129
HYD TEST SWITCH J1 P171
J1 P117 P172 J6
3 SYS 1 J155 P155
83
2 L 84
OFF
M 85 86 R
1 SYS 2 GS107-B E S
N 86
AOG RELAY
K1-7/8
B3
B1 B2
A620
CB48 W124 A2
A1
CFU 7
J2 P374
5A 37 6 6
X1 X2
HYD TEST
8
RIGHT
A401
GENERATOR MANIFOLD/
BUS 87 RESERVOIR 2
P425 J3
A SYS SELECT
A2 A612 W123
B SOLENOID
IIDS W122 FWD INTERCONNECT PANEL
J155 P155
P421 J1
P170 J9 J1 P171
J5 P105 E T B
TEMP SWITCH
GS107-E A
HYD OIL TEMP 2 HI R 83 84 U
P423 J2
J3 P103 Q
Q Q Q Q Q Q Q
HYD OIL PRESS 2 EXCIT HI 15 84 85 V A
HYD OIL PRESS 2 EXCIT LO 16 85 87 X B PRESS XDCR
HYD OIL PRESS 2 HI 17 86 88 Y C
HYD OIL PRESS 2 LO 18 87 89 W D
6 SEE ELECTRICAL INTERCONNECT DIAGRAM 98-40-00

7 900 CONFIG
8 902 CONFIG 9G29-004-2B
Figure 102. Hydraulic System 2 Wiring Diagram
Page 104
Original 29-00-00
HYDRAULIC SYSTEM
1. Hydraulic System Inspection/Test (3). Inspect for chafed, deteriorated, cut,
frayed and/or cracked hoses. None
A. Hydraulic System Inspection allowed.
(Ref. Figure 201) (4). Inspect for loose, broken and/or cracked
clamps. None allowed.
(1). Inspect exterior surfaces of hydraulic
components for nicks, gouges, (5). Inspect manifold/reservoir fluid level;
scratches, cracks and corrosion. Service as required. Replace contami
nated filters.
(a). Minor scratches, without burrs or
raised material, that do not pene (6). Inspect electrical components.
trate through protective finish are (a). Foreign objects and corroded, bent
acceptable without rework. broken, loose or missing pins. None
(b). Nicks, gouges, corrosion pits or other allowed.
minor surface damage that does not (b). Dirt, contamination with fluid or
exceed a depth of 0.040-inch (0.102 rough locking action. None allowed.
cm) or 10 percent of material thick
ness, whichever is less after rework, (c). Wire harness for chafing and loose
are permissible. installation. None allowed.
(c). No cracks are allowed. (7). If pump is known to have operated

without fluid for 30 seconds or more,
(d). No mating or working surface repair replace the pump and remove and
is allowed. inspect filter elements for metallic
particles.
(e). Touchup removed protective finish as
required (Ref. Section 20-40-00). (8). Inspect fittings for crossed, burred and
stripped threads when hoses and tubes
(f). Replace components if damage are disconnected. None allowed. Cap or
exceeds repairable limits, or if plug all disconnected fittings. Plug all
damage occurs on an oil seal surface, open ports. To indicate exact location,
radius, in a hole or on a mating or identify ends before disconnecting lines
working surface of a part. and hoses.
(2). Inspect for chafed, cracked, dented, B. Hydraulic System Pressure Leak Test
nicked and scratched tubes.
(1). No external leakage is allowed except
(a). Replace entire tube assembly if at servocylinder gland seals. Perform
tubing is deformed and if nuts and the following to determine if the
unions are damaged. leakage is excessive:
(b). Replace tube assembly if tube is (a). Slight wetting at seals or signs of
dented more than 10 percent of the fluid insufficient to form a drop is
tube diameter. considered as seepage or residual
fluid and is not external leakage.
(c). Replace tube assembly if nicked or
chafed more than 10 percent of the (b). Wipe servocylinders clean of any fluid
tube wall thickness. at the gland seals and weep holes.
(c). Attach GSE cart to hydraulic system
(d). Torque screws until mating rubber 1 and 2 GSE panel (Ref. Figure 201).
cushions just contact when reinstal
ling rubber cushioned tubing clamp (d). Apply 500 psig external hydraulic
blocks. pressure to system 1 and 2.
Page 201
29-00-00 Original
(e). Operate flight controls through a (2). Perform hydraulic system check per
minimum of 25 full-stroke cycles current Rotorcraft Flight Manual
with the hydraulic system pressur (Ref. Section 01-00-00, Table 201).
ized.
(3). Shut down helicopter per current
(f). Leakage at the gland seals or at Rotorcraft Flight Manual (Ref. Section
weep holes shall not exceed 1 drop 01-00-00, Table 201).
per 25 cycles.
E. Hydraulic System Functional Test (with
(g). Depressurize system and remove GSE Pressure).
GSE cart (Ref. Figure 201). (1). Apply power to dc buses and close IIDS
circuit breaker (Ref. Section 96-00-00).
(2). Operate pumps by ground running
helicopter on one engine at idle (65%) (2). Verify 1 HYD 2 caution segments
RPM per current Rotorcraft Flight illuminate on IIDS panel.
Manual (Ref. Section 01-00-00,
Table 201) and inspect the pumps seal (3). Select HYD PRESS on IIDS alphanu
drain for a maximum seepage of 5 meric display (Ref. Section 95-00-00).
drops in 3 minutes. (4). Apply 1000 psig external hydraulic
pressure to system 1 (Ref. Section
C. Hydraulic System Static Leak Test
29-00-00).
NOTE: Leakages are based on a static leakage (5). Slowly decrease pressure to 200 psig
rate of 10 drops per dynamic seal. and then slowly increase pressure to
1000 psig.
(1). When main rotor control actuator
leakage is observed on aircraft standing NOTE: Hydraulic system 2 caution segment
idle, the following procedure shall be should remain illuminated throughout this
used to determine if leakage is unac portion of test.
ceptable:
(a). Verify pressure indication on IIDS
(2). Wipe actuator and clean up any fluid panel alphanumeric display.
spillage.
(b). Verify that hydraulic system 1
(3). Re-inspect in 24 hours. Accumulated caution segment illuminates before
leakage from any of the three servoac 250 psig and that segment goes out
tuators shall not exceed the equivalent at or before 510 psig.
of one teaspoon or roughly a fluid spot (6). Remove external hydraulic pressure
not exceeding eight inches in diameter. and disconnect GSE cart from system 1
GSE ports (Ref. Section 29-00-00).
D. Hydraulic System Operational Test
(Aircraft Ground Run) (7). Turn off dc power (Ref. Section
96-00-00).
(1). Ground run helicopter per current
Rotorcraft Flight Manual (Ref. Section (8). Repeat Steps E-1 through E-8 for
01-00-00, Table 201). system 2.
Page 202
2 3
SYSTEM NO. 2
2
1
SYSTEMS 1 AND 2 SHOWN

SEPARATELY FOR CLARITY 4
SYSTEM NO. 1
9G29-012
1. GSE PANEL 3. VARIABLE DELIVERY PUMPS
2. MANIFOLD/RESERVOIR 4. DIRECTIONAL ACTUATOR
Figure 201. Hydraulic Systems 1 and 2
Page 203
29-00-00 Original
2. Hydraulic System Pressure Application Do not exceed 1000 psig dur

WARNING ing application of external
A. External Hydraulic Pressure Application hydraulic pressure. Do not set pres
sure below 350 psig.
Consumable Materials Use extreme care when adjust

CAUTION ing hydraulic pressure to avoid
(Ref. CSPSPM)
Item Nomenclature damage to the helicopters hydraulic system.
C112 Hydraulic Fluid (5). Preset hydraulic mule pressure before
applying pressure to helicopter system.
(Refer to applicable rigging/test
instructions for proper pressure
Special Tools setting.)
(Ref. CSPSPM)
(6). On helicopters with 900H381502-105
Item Nomenclature
hydraulic manifolds, rapidly increase
T2001 Hydraulic Mule pressure from 0 - 250 psi to prevent
fluid venting overboard due to reservoir
overfilling.
(1). Open transmission forward left-hand
(7). Apply hydraulic mule pressure to
access door L155 (Ref Section
helicopter hydraulic system.
06-00-00).
Do not make full or abrupt
CAUTION movements of the main rotor
flight controls with external hydraulic pow
er applied to aircraft. The main rotor flex
beams cannot accommodate full control ex
cursions (combinations of full collective and
full cyclic movements) without centrifugal
Do not mix different specifica force.
CAUTION tion hydraulic fluids. Ensure
(8). Perform applicable system rigging/test.
that only hydraulic fluid (C112) is used to
service the hydraulic systems for all helicop (9). When rigging/test is complete; on
ter operations in temperatures above -40F. helicopters with 900H381502-105
Hydraulic Manifolds, rapidly decrease
(2). Select GSE panel for system which pressure from 250 -0 psi to prevent
requires application of external pres fluid venting overboard due to reservoir
sure. Connect pressure and return lines overfilling.
from hydraulic mule (T2001) to pres (10). Discontinue pressure application from
sure and return ports on GSE panel. hydraulic mule. Shut off hydraulic
mule.
NOTE: The GSE return port must be connected
before applying pressure to prevent fluid NOTE: Disconnect GSE pressure line prior to
venting overboard due to reservoir overfil disconnecting the return line, to prevent
ling. fluid venting overboard due to reservoir
overfilling.
(3). Remove drain tube from BL port fitting (11). Disconnect hydraulic mule pressure
on manifold/reservoir of selected system and return lines from GSE panel and
and clamp an approximate 9 foot length install panel port covers.
of flex tubing to BL port fitting. Place
other end of flex tube into a bucket. (12). Remove flex tubing from manifold BL
port fitting and reconnect drain tube.
(4). Open bleed valve until all fluid is (13). Close transmission forward left-hand
drained from manifold. Close bleed access door L155 (Ref Section
valve. 06-00-00).
Page 204
3. Hydraulic Ground Support Equipment C. Hydraulic GSE Panel Installation

(GSE) Panel
(Ref. Figure 202)
A. Hydraulic GSE Panel Removal
(Ref. CSPSPM)
NOTE: System 1 and System 2 GSE panel re Item Nomenclature
moval typical. C112 Hydraulic Fluid
(1). Open L155 (Ref Section 06-00-00). C232 Sealant
(2). Put rags on transmission deck below

GSE tubes to catch hydraulic fluid (1). Put GSE panel in its installed position.
spills.
(2). Install bolts and washers. Torque bolts.
Sealant (C232)
(3). Remove GSE panel (1).

(3). Mix sealant (C232) (Ref. manufactur
(a). Disconnect pressure tube (2). er's instructions).
(b). Disconnect return tube (4). (4). Apply a fillet bead of sealant along edge
of panel.
(c). Remove bolts (6) and washers (7).
Remove GSE panel. (5). Remove protective caps from tube and
coupling port fittings.
(4). Install protective caps on all fittings.
(5). Remove rags from transmission deck.
B. Hydraulic GSE Panel Inspection
(Ref. Figure 202)
(1). Inspect tube end fittings, GSE panel (6). Lubricate threads of couplings with
couplings, and caps for cracks, rounded clean hydraulic fluid (C112).
flats, and damaged threads. None (7). Connect return tube. Torque coupling
allowed. nut.
(2). Inspect GSE panel for dents, nicks, (8). Connect pressure tube. Torque coupling
cracks, and corrosion. None allowed. nut.
(3). Inspect coupling cap lanyards for wear (9). Service and leak test hydraulic system.
and security of attachment. No damage
allowed. (10). Close L155 (Ref. Section 06-00-00).
Page 205
3
5 1
2
7
9G29-002
1. HYDRAULIC GSE PANEL 5. RETURN PORT QUICK DISCONNECT COUPLING

2. PRESSURE TUBE 6. BOLTS
3. PRESSURE PORT QUICK DISCONNECT COUPLING 7. WASHERS
4. RETURN TUBE
Figure 202. Hydraulic Ground Support Equipment (GSE) Panel
4. Hydraulic Pump Hydraulic Fluid (C112)
A. Hydraulic Pump Removal
(Ref. Figure 203)

(4). Empty both system reservoirs through
(1). Remove transmission forward access manifold bleed valve.
door assembly L155 or R155. Remove
swashplate forward fairing assembly (5). Slowly loosen pump pressure hose (1) at
T155 (Ref. Section 06-00-00). pump until fluid begins to seep from
fitting.
(2). Locate pump.
(6). From bleed valve on manifold within
(a). System No. 1 pump is on transmis the same system as the pump being
sion forward, left-hand accessory removed, drain fluid until fluid stops
drive pad. seeping from loosened pump pressure
fitting.
(b). System No. 2 pump is on transmis (7). Slowly loosen hose (5) from pump
sion forward, right-hand accessory control port fitting until fluid begins to
drive pad. seep.
(3). Place rags on transmission deck (8). Drain fluid from manifold bleed valve of
beneath hydraulic pump to catch opposite system until fluid stops
hydraulic fluid spills. seeping.
Page 206
(9). Disconnect port fitting hoses. C. Hydraulic Pump Installation

(a). Disconnect hose (1) from pump (Ref. Figure 203)
pressure port fitting.
(b). Disconnect hose (2) from pump (Ref. CSPSPM)
suction port fitting. Item Nomenclature
(c). Disconnect hose (3) from case drain C112 Hydraulic Fluid
port fitting. C702 Lockwire
(d). Disconnect flexible drain tube (4)

from pump seal drain port fitting. (1). Remove FOD cover from transmission
accessory drive pad.
(e). Disconnect hose (5) from pump
control port fitting. Hydraulic Fluid (C112)
(10). Install protective caps on all hoses and

pump port fittings.
(11). Remove pump. (2). Mount pump on drive pad.
(a). Remove nuts (6) and washers (7) (a). Lightly lubricate new packing (9)
from studs securing pump (8) to with clean hydraulic fluid (C112),
transmission accessory drive assem and install packing in groove on
bly. mounting flange of pump (8).
(b). Slide pump from studs. Remove and (b). With pump data plate facing up,
discard packing (9) from pump carefully slide pump onto studs of
mounting flange. drive pad, engaging drive shaft
splines with drive assembly splines.
(c). Install FOD cover on open drive
assembly. (c). Install washers (7) and nuts (6) on
drive pad studs. Torque nuts.
(12). Remove rags from transmission deck.
(3). Connect port fitting hoses.
B. Hydraulic Pump Inspection (a). Remove protective caps from hoses
(Ref. Figure 203) and pump port fittings. Lubricate
port fittings with clean hydraulic
(1). Inspect pump hose port fittings for fluid (C112).
stripped or damaged threads. None
(b). Connect pressure hose (1) to pump
allowed.
pressure port fitting. Torque hose
(2). Inspect pump drive shaft for worn or fitting.
damaged splines. None allowed. (c). Connect suction hose (2) to pump
suction port fitting. Torque hose
(3). Replace packing between pump and
fitting.
drive assembly when pump is removed.
(d). Connect case drain hose (3) to pump
(4). Inspect face of accessory drive pad for case port fitting. Torque hose fitting.
damage. None allowed.
(e). Connect drain tube fitting (4) to
(5). Inspect accessory drive pad seal for pump seal drain port. Torque tube
leaks. Leakage rate must not exceed fitting.
2cc per hour or one drop per minute.
(f). Ensure clamp which secures flexible
(6). Inspect hoses for nicks, cuts, chafing drain tube to drain tube fitting is
and stripped threads. None allowed. tight.
Page 207
(g). Connect pump control hose (5) to (7). Safety all hose fittings with lockwire
pump control port fitting. Torque (C702).
hose fitting.
(8). If necessary, service both hydraulic
(4). Service both hydraulic systems (Ref. systems (Ref. Section 12-00-00).
Section 12-00-00).
(9). Pressure leak test both hydraulic
(5). Slowly loosen pump control hose (5) systems (Ref. Section 29-00-00).
fitting until fluid begins to seep from
fitting. Allow fluid to drain until air is (10). Install swashplate forward fairing
bled from line. assembly T155. Install and close
forward access door L155 or R155 (Ref
(6). Torque pump control hose (5) fitting. Section 06-00-00).
2 5
4
8 7 (4 PL)
6 (4 PL)
NOTE: PUMP PORT FITTINGS AND ATTACHING HARDWARE 9

ARE TYPICAL FOR BOTH PUMP #1 AND #2 9G29-007
1. PUMP PRESSURE HOSE 6. NUTS
2. PUMP SUCTION HOSE 7. WASHERS
3. PUMP CASE DRAIN HOSE 8. HYDRAULIC PUMP
4. FLEXIBLE DRAIN TUBE 9. PACKING
5. PUMP CONTROL TUBE
Figure 203. Hydraulic Pump Removal/Installation
Page 208
5. Hydraulic Manifold/Reservoir Residual Fluids

CAUTION
A. Hydraulic Manifold/Reservoir Removal
(7). Disconnect tube and hose fittings from
(Ref. Figure 204) manifold.
(a). Disconnect hose from manifold PMP
NOTE: Removal of manifold/reservoir No. 1 PRESS port fitting (7).
and No. 2 is typical, except where noted.
(b). Disconnect hose from manifold PMP
(1). Remove transmission forward access SCT port fitting (8).
door assembly L155 or R155. Remove
swashplate forward fairing assembly (c). Disconnect tube from manifold BL
T155 (Ref. Section 53-30-00). port fitting (9).
(2). Place rags on transmission deck (d). Disconnect hose from manifold CS
beneath manifold/reservoir to catch DR port fitting (10).
hydraulic fluid spills. (e). Disconnect tube from manifold
PRESS port fitting (11).
(f). Disconnect tube from manifold RTN
port fitting (12).
(g). Disconnect tube from manifold GSE
PRESS port fitting (13).
(3). Drain all hydraulic fluid, as practical,
from manifold/reservoir through bleed (h). Disconnect tube from manifold GSE
valve. RTN port fitting (14).
(8). Install protective caps on all tubes,
(4). For removal of manifold/reservoir
hoses and manifold fluid port fittings.
No. 1, detach the following electrical
connectors. (9). Remove manifold/reservoir.
(a). Detach connector P427 from temper (a). Remove bolts (15) and washers (16)
ature switch (1). from base of support bracket and lift
manifold/reservoir assembly from the
(b). Detach connector P428 from pressure deck.
transducer (2).
(b). Remove rags and clean any spilled
(c). Detach connector P429 from system fluid from transmission deck.
select solenoid (3). (c). Clean dried sealant from edges of
manifold support bracket and
(5). For removal of manifold/reservoir mounting surface of deck.
No. 2, detach the following electrical
connectors. B. Hydraulic Manifold/Reservoir Inspection
(a). Detach connector P421 from temper (Ref. Figure 204)

ature switch (1).
(1). Inspect hydraulic manifold fluid port
fittings for stripped or damaged
(b). Detach connector P423 from pressure
threads; None allowed.
transducer (2).
(2). Inspect all electrical connectors and
(c). Detach connector P425 from system receptacles for damage or corrosion;
select solenoid (3). None allowed.
(6). Install protective caps on all electrical (3). Inspect fluid level sight glass for cracks,
connectors and receptacles. crazing or discoloration. Replace
Page 209
manifold/reservoir if sight glass is Hydraulic Fluid (C112)

leaking or visual reference is impaired.
(4). Inspect tubes and hoses for chafing and
stripped or damaged threads. None
allowed. (3). Connect tube and hose fittings to
manifold.
(5). Inspect mounting surface of manifold
and deck for corrosion. None allowed. (a). Remove protective caps from all
hydraulic lines and manifold fluid
C. Hydraulic Manifold/Reservoir Installation port fittings. Lubricate threads of
manifold fluid port fittings with clean
(Ref. Figure 204)
hydraulic fluid (C112).
NOTE: Installation of manifold/reservoir No. 1 (b). Connect GSE return tube to manifold
and No. 2 is typical, except where noted. GSE RTN port (14). Torque tube
fitting.
Consumable Materials (c). Connect GSE pressure tube to
(Ref. CSPSPM) manifold GSE PRESS port (13).
Item Nomenclature Torque tube fitting.
(d). Connect system return tube to
C232 Sealant
manifold RTN port (12). Torque tube
C702 Lockwire fitting.
(e). Connect system pressure tube to
(1). Mount manifold/reservoir to transmis manifold PRESS port (11). Torque
sion deck. tube fitting.
(a). Position manifold/reservoir No. 1 on (f). Connect pump suction hose to
transmission deck, beneath forward, manifold PMP SCT port (8). Torque
left-hand leg of rotor support assem hose fitting.
bly.
(g). Connect pump pressure hose to
(b). Position manifold/reservoir No. 2 on manifold PMP PRESS port (7).
transmission deck, beneath forward, Torque hose fitting.
right-hand leg of rotor support (h). Connect pump case drain hose to
assembly. manifold CS DR port (10). Torque to
hose fitting.
(c). Align bolt holes in manifold/reservoir
support bracket with nutplates on (i). Connect drain tube to manifold BL
the deck. port (9). Torque tube fitting.
(d). Secure manifold/reservoir assembly (4). Safety all tube and hose fittings with
to the deck with bolts (15) and lockwire (C702).
washers (16). Torque bolts.
(5). Remove protective caps from electrical
Sealant (C232) connectors and receptacles.
(6). For installation of manifold/reservoir
No. 1, attach the following electrical
connectors.
(a). Attach connector P427 to tempera
(2). Mix sealant (C232) per manufacturer's ture switch (1).
instructions and apply a fillet bead of
sealant along edge of manifold-to-deck (b). Attach connector P428 to pressure
mating surface. transducer (2).
Page 210
(c). Attach connector P429 to system Hydraulic Fluid (C112)

select solenoid (3).
(7). For installation of manifold/reservoir

No. 2, attach the following electrical
connectors. (3). Loosen filter bowl from manifold using
hex flats at bottom of bowl.
(a). Attach connector P421 to tempera
ture switch (1). (4). After locking flange at top of filter bowl
is clear of lock lever, release lock lever
and continue to thread bowl from
(b). Attach connector P423 to pressure
manifold.
transducer (2).
(5). Lower filter element into filter bowl
(c). Attach connector P425 to system and remove element and bowl from
select solenoid (3). transmission deck.
(8). Service hydraulic system (Ref. Section (6). Remove and discard packing.
12-00-00). (7). Remove filter element and compression
spring from bowl.
(9). Pressure leak test hydraulic system
(Ref. Section 29-00-00). (8). Deposit residual hydraulic fluid from
bowl into hazardous waste disposal
(10). Install swashplate forward fairing container.
assembly T155. Install and close B. Hydraulic Manifold/Reservoir Filter and
forward access door assembly L155 or Bowl Assembly Installation
R155. (Ref. Section 53-30-00).
(Ref. Figure 204)
6. Hydraulic Manifold/Reservoir Filter and NOTE: This task is typical for System 1 left
Bowl Assembly side and System 2 right side, except where
noted.
A. Hydraulic Manifold/Reservoir Filter and
Bowl Assembly Removal
(Ref. CSPSPM)
NOTE:
This task is typical for System 1 left side
and System 2 right side, except where Hydraulic Fluid (C112)
noted.
Each hydraulic manifold/reservoir has
two filter and bowl assemblies, one on ei
ther side of the manifold fluid level sight (1). Reset Delta P indicator, if applicable
glass. Removal procedures are typical for (Ref Section 29-00-00).
either assembly.
(2). Install compression spring into filter
(1). Open transmission forward access door bowl.
assembly L155 or R155. (Ref. Section
(3). Install new filter element, open end up,
53-30-00).
into filter bowl.
(2). Depress and hold spring-loaded lock (4). Lubricate new packing with hydraulic
lever located on the manifold above fluid (C112) and install atop flange of
filter bowl assembly. bowl.
Page 211
(5). Slide filter bowl beneath hydraulic (b). P423 on manifold/reservoir No. 2.
manifold filter port.
Residual Fluids
CAUTION
(6). Raise bowl and engage threads of bowl
with threads of manifold filter port.
(6). Remove transducer (2) and perform
(7). Depress and hold lock lever while Hydraulic Pressure Transducer
threading filter bowl into manifold. Inspection (Ref. Section 29-00-00).
Tighten hand tight and release lock
B. Hydraulic Pressure Transducer
lever.
Inspection
(8). Service hydraulic system (Ref. Section (1). Inspect electrical connector for damage.
12-00-00). None allowed.
(9). Verify no leaks are present in flam (2). Inspect electrical receptacle for damage.
mable fluid systems, where mainte None allowed.
nance or replacement of components,
lines, or fittings has occurred, by (3). Inspect transducer and manifold/reser
application of system pressure and voir for stripped or damaged threads.
visual inspection prior to helicopter None allowed.
being returned to service.
C. Hydraulic Pressure Transducer
(10). Close forward access door L155 or R155 Installation
(Ref Section 06-00-00).
(Ref. Figure 204)
7. Hydraulic Pressure Transducer NOTE: This task is typical for left or right hand
transducers except where noted.
A. Hydraulic Pressure Transducer Removal
(Ref. CSPSPM)
NOTE: This task is typical for System 1 left Item Nomenclature
side and System 2 right side, except where
noted. C112 Hydraulic Fluid
C702 Lockwire
(1). Open forward access door L155 or R155
(2). Place rags on transmission deck
beneath manifold/reservoir to catch
hydraulic fluid spills.
Hydraulic Fluid (C112) (1). Lubricate new packing and pressure
transducer (2) with hydraulic fluid
(C112). Install packing on transducer.
(2). Install and torque transducer (2).
(3). Drain all hydraulic fluid, as practical, Safety transducer with lockwire (C702).
from manifold/reservoir through bleed (3). Apply torque stripe to transducer (2),
valve. (Ref. CSP-SPM, Section 20-10-00,
Identification Stripe).
(4). Cut and discard lockwire from pressure
transducer (2). (4). Attach electrical connector.
(5). Detach electrical connector. (a). P428 on manifold/reservoir No. 1.
(a). P428 on manifold/reservoir No. 1. (b). P423 on manifold/reservoir No. 2.
Page 212
(5). Service hydraulic system (Ref. Section C. Hydraulic Temperature Switch

12-00-00). Installation
(6). Verify no leaks are present in flam (Ref. Figure 204)
mable fluid systems, where mainte
nance or replacement of components, NOTE: This task is typical for System 1 left
lines, or fittings has occurred, by side and System 2 right side, except where
application of system pressure and noted.
visual inspection prior to helicopter
being returned to service. Consumable Materials
(Ref. CSPSPM)
(7). Close forward access door L155 or R155
Item Nomenclature
8. Hydraulic Temperature Switch C702 Lockwire
A. Hydraulic Temperature Switch Removal
(Ref. Figure 204)
NOTE: This task is typical for System 1 left
side and System 2 right side, except where
noted.
(1). Lubricate new packing and tempera
(1). Open forward access door L155 or R155 ture switch with hydraulic fluid (C112).
(Ref. Section 53-30-00). Install packing on switch.
(2). Detach electrical connector. (2). Install and torque temperature switch.
(a). P427 on manifold/reservoir No. 1. (3). Safety temperature switch with
(b). P421 on manifold/reservoir No. 2. lockwire (C702).
(3). Cut and discard safety wire. (4). Remove rags and clean any spilled fluid
from transmission deck.
Residual Fluids
CAUTION (5). Attach electrical connector.
(4). Place rags on transmission deck (a). P427 on manifold/reservoir No. 1.

beneath manifold/reservoir to catch (b). P421 on manifold/reservoir No. 2.
hydraulic fluid spills.
(6). Service hydraulic system (Ref. Section
(5). Remove temperature switch (1) 12-00-00).
B. Hydraulic Temperature Switch Inspection (7). Verify no leaks are present in flam
(1). Inspect electrical connector for damage. mable fluid systems, where mainte
None allowed. nance or replacement of components,
lines, or fittings has occurred, by
(2). Inspect electrical receptacle for damage. application of system pressure and
None allowed. visual inspection prior to helicopter
(3). Inspect temperature switch and
manifold for stripped or damaged (8). Close forward access door L155 or R155
threads. None allowed. (Ref. Section 53-30-00).
Page 213
4
3
5
9 1
55 -65 in-lb
6.2 - 7.3 Nm 2
11
12
10
8
13
14
6
15 (3 PL)
16 (3 PL) 9G29-010A
1. TEMPERATURE SWITCH 9. BLEED (BL) PORT

2. PRESSURE TRANSDUCER 10. CASE DRAIN (CS DR) PORT
3. SYSTEM SELECT SOLENOID 11. SYSTEM PRESSURE (PRESS) PORT
4. BYPASS (DELTA P) INDICATOR 12. SYSTEM RETURN (RTN) PORT
5. ISOLATION VALVE 13. GSE PRESSURE (GSE PRESS) PORT
6. FILTER BOWLS 14. GSE RETURN (GSE RTN) PORT
7. PUMP PRESSURE (PMP PRESS) PORT 15. BOLT
8. PUMP SUCTION (PMP SCT) PORT 16. WASHER
Figure 204. Hydraulic Manifold/Reservoir
Page 214
9. Manifold Filter Bypass (Delta P) Indicator C. Bypass (Delta P) Indicator Removal

A. Filter Bypass (Delta P) Indicator Reset (Ref. Figure 205)
(Ref. Figure 204) NOTE: This task is typical for system 1 and
system 2, unless noted.
NOTE: This task is typical for System 1 and
System 2, unless noted. (1). Open Access Door L155 or R155 (ref.
Section 06-00-00).
(1). Open Access Door L155 or R155 (ref.
(2). Remove lockwire from screws (3).
Section 06-00-00).
(2). Remove manifold/reservoir filter and
bowl. (4). Put rags on transmission deck below
manifold/reservoir to catch hydraulic
(3). Push up on piston in center of manifold fluid.
filter port and then release.
(4). Make sure bypass (delta P) indicator
has reset (is in).
(5). Install manifold/reservoir filter bowl
and new filter element.
(5). Remove bypass (delta P) indicator (1).
(6). Close Access Door L155 or R155 (ref.
(6). Remove and discard indicator packings
Section 06-00-00).
(5, 6, 7).
B. Bypass (Delta P) Indicator Cleaning D. Bypass (Delta P) Indicator Installation
NOTE: This task is typical for system 1 and NOTE: This task is typical for System 1 and
system 2, unless noted. System 2, unless noted.
(1). Remove bypass (delta P) indicator (1).
Solvent (C434) (Ref. CSPSPM)
Item Nomenclature
Alcohol, Isopropyl (C419) C434 Solvent
C702 Lockwire

(2). Clean indicator, use isopropyl alcohol
(C419) or solvent (C434).
Protective Equipment
(1). Lubricate new packings (5, 6, 7) with
hydraulic fluid (C112) and install on
indicator (1).
(3). Remove dirt from indicator, use air gun (2). Install indicator.
with low pressure dry air 20-30 psig (3). Install washers and screws.
(138-207 kPa).
(a). Torque screws 35 to 45 in-lb (3.95
(4). Install indicator. to 5.08 Nm).
Page 215
(4). Safety screws with lockwire (C702). (11). Close Access Door L155 or R155 (ref.
Section 06-00-00).
(5). Make sure bypass (delta P) indicator is
in. If necessary, reset bypass (delta P)
indicator.
11. System Select Solenoid
(6). Remove rags and if necessary, clean
transmission deck.
A. System Select Solenoid Removal
(7). Service hydraulic system (ref. Section
12-00-00).
(Ref. Figure 205)
(8). Do the Hydraulic System Pressure
Leak Test, look at the bypass (delta P)
indicator for leaks. NOTE: This task is typical for system 1 and
system 2, unless noted.
Section 06-00-00).
(1). Open Access Door L155 or R155 (ref.
10. Bleed Valve Section 06-00-00).
A. Bleed Valve Packing Replacement

(2). Disconnect electrical connector from
(Ref. Figure 205) solenoid (11) as follows:
NOTE: This task is typical for system 1 and
system 2, unless noted. (a). P429 on manifold/reservoir No. 1.
(1). Open access door L155 or R155 (ref.
Section 06-00-00). (b). P425 on manifold/reservoir No. 2.
(2). Remove safety wire from bleed valve
(8). (3). Remove sealant from solenoid flange
(13).
(3). Remove bleed valve (8).
(4). Discard packings (9 and 10).
(4). Remove safety wire from screws (12).
(5). Remove screws (12).
(6). Put rags on transmission deck below

(5). Lubricate new packings (9 and 10) with manifold/reservoir to catch hydraulic
hydraulic fluid (C112) and install on fluid.
bleed valve.
(6). Install bleed valve. Hydraulic Fluid (C112)
(7). Torque bleed valve 55 to 65 in-lb (6.21
to 7.34 Nm).
(8). Safety valve with lockwire (C702).
12-00-00). (7). Remove solenoid (11).
Leak Test, look at the bleed valve for (8). Discard packing (15) and two retainers
leaks. (16).
Page 216
B. System Select Solenoid Installation (4). Install screws.

(Ref. Figure 205) (a). Torque screws 10 to 12 in-lb (1.13
to 1.35 Nm).
NOTE: This task is typical for System 1 and
System 2, unless noted. (5). Safety screws with lockwire (C702).
(6). Connect electrical connector to solenoid
as follows:
(Ref. CSPSPM)
Item Nomenclature (a). P429 on manifold/reservoir No. 1.
(b). P425 on manifold/reservoir No. 2.
C702 Lockwire (7). Environmentally seal around flange of
solenoid with sealant (C216) (ref.
(8). Remove rags and if necessary, clean
transmission deck.
(1). Lubricate new packing with hydraulic 12-00-00).
fluid (C112) and install with two new
retainers on solenoid.
Leak Test, look at the select solenoid for
NOTE: Some select solenoid installations do leaks.
not have gasket (14) installed.
(2). Install flange and gasket (if available) Section 06-00-00).
on solenoid.
(12). Do the Hydraulic System Operational
(3). Install solenoid. Test.
Page 217
3
2
5 4
8
1
9
7
10
11
14
13
16
15 12
16
9g29-014B
1. BYPASS (DELTA P) INDICATOR 9. PACKING

2. COVER 10. PACKING
3. SCREW 11. SOLENOID
4. WASHER 12. SCREW
5. PACKING 13. FLANGE
6. PACKING 14. GASKET
7. PACKING 15. PACKING
8. BLEED VALVE 16. RETAINER
Figure 205. Hydraulic Manifold/Reservoir Component Replacement
Page 218
12. Hydraulic Hand Pump (Optional) (3). Inspect hand pump reservoir for leaks
and evidence of possible fluid contami
A. Hydraulic Hand Pump Removal nation. None allowed.
(Ref. Figure 206)
(4). Inspect reservoir sight glass for cracks,
(1). Open transmission forward access door crazing and discoloration. Replace hand
assembly L155 (Ref. Section 06-00-00). pump if sight glass is leaking or visual
reference is impaired.
C. Hydraulic Hand Pump Installation
(Ref. Figure 206)
(2). Place a small container on transmission Consumable Materials

deck beneath hand pump (1) outlet (Ref. CSPSPM)
ports to catch hydraulic fluid spills. Item Nomenclature
(3). Remove hydraulic hand pump. C112 Hydraulic Fluid
(a). Set hand pump system select lever

(2) to system No. 2 to minimize fluid (1). Remove protective caps from end
spillage when system No. 1 fill tube fittings of tubes (3 and 4) and port
(3) is disconnected from pump (1). fittings of pump (1).
(b). Disconnect system No. 1 fill tube (3) Hydraulic Fluid (C112)
from upper port fitting of pump (1)
and install protective caps on open
fittings of tube and upper outlet port
of pump.
(c). Set hand pump system select lever (2). Install hydraulic hand pump.
(2) to system No. 1.
(a). Align pump (1) with nutplate holes
(d). Disconnect system No. 2 fill tube (4) on left-hand edge of transmission
from lower port fitting of pump (1) deck, just aft of hydraulic system
and install protective caps on open GSE panel.
fittings of tube and lower outlet port
of pump. (b). Install bolts (5) and washers (6).
Torque bolts.
(e). Remove bolts (5) and washers (6) to
remove pump from transmission (c). Lubricate threads of pump port
deck. fittings with clean hydraulic fluid
(C112).
(4). Install protective caps on open tube
fittings (3 and 4). (d). Connect system No. 2 pump fill tube
(4) to lower port fitting of pump (1).
(5). Remove container and clean any spilled
Torque tube fitting.
hydraulic fluid from transmission deck.
B. Hydraulic Hand Pump Inspection (e). Connect system No. 1 pump fill tube
(3) to upper port fitting of pump
(1). Inspect tube end fitting(s) and pump (1).Torque tube fitting.
port fitting(s) for nicks, dents, cracks,
rounded flats and stripped or damaged (3). Service hydraulic system (Ref. Section
threads. None allowed. 12-00-00).
(2). Inspect hand pump and attaching (4). Close transmission forward access door
surfaces for corrosion. None allowed. assembly L155 (Ref. Section 06-00-00).
Page 219
5 (4 PL)
6 (4 PL) 3
VIEW ROTATED
2 9G29-009
1. HAND PUMP 4. SYSTEM NO.2 FILL TUBE
2. SYSTEM SELECT LEVER 5. BOLT
3. SYSTEM NO. 1 FILL TUBE 6. WASHER
Figure 206. Hydraulic Hand Pump (Optional)
Page 220
Chapter
LANDING GEAR
TABLE OF CONTENTS
32-00-00 Landing Gear Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A

1. Standard Landing Gear Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
A. Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
B. Forward and Aft Crosstubes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
C. Forward and Aft Saddle Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
D. Side Stop Clamp Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
E. Forward Spacer Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
F. Landing Gear Damper Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
G. Skid Tubes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Figure 1.Landing Gear Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Fault Isolation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
1. Standard Landing Gear Assembly Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Table 101.Standard Landing Gear Assembly Troubleshooting . . . . . . . . . . . . . . 101
1. Forward LH and RH Side Stop-Clamp Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
A. Removal of the Forward Stop-Clamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
B. Installation of the Forward Stop-Clamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
Figure 401.Removal and Installation of the Forward Stop-Clamps . . . . . . . . . . 402
Figure 402.Removal and Installation of the Aft Stop-Clamps . . . . . . . . . . . . . . . 404
2. Landing Gear (Aft) LH and RH Side Stop-Clamp Assemblies . . . . . . . . . . . . . . . . . . 405
A. Removal of the Aft Stop-Clamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 405
B. Installation of the Aft Stop-Clamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 405
Figure 403.Removal and Installation of the Landing Gear Assembly . . . . . . . . . 406
3. Standard Landing Gear Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 407
A. Removal of the Landing Gear Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 407
B. Installation of the Landing Gear Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 407
4. Aft LH and RH Saddle Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 408
A. Removal of the Aft Saddles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 408
B. Installation of the Aft Saddles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 408
5. LH and RH Forward Saddle Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 408
A. Removal of the Forward Saddles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 408
B. Installation of the Forward Saddles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 408
6. Landing Gear Saddle Pads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 409
A. Removal of the Saddle Pads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 409
B. Installation of the Saddle Pads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 409
Page i

Figure 404.Assembly and Disassembly of the Landing Gear Assembly . . . . . . . 410
7. Assembly and Disassembly of the Standard Landing Gear Assembly . . . . . . . . . . . 411
A. Removal of the Forward Spacer Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 411
B. Installation of the Forward Spacer Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 411
C. Removal of the Damper Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 411
D. Installation of the Damper Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 411
E. Removal of the Skid Tube Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 412
F. Installation of the Skid Tube Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 412
G. Removal of the Aft Crosstube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 413
H. Installation of the Aft Crosstube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 413
I. Removal of the Forward Crosstube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 413
J. Installation of the Forward Crosstube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 413
Figure 405.Skid Tube Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 414
8. Assembly and Disassembly of the LH and RH Skid Tube Assemblies . . . . . . . . . . . 415
A. Removal of the Forward Abrasion Strips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 415
B. Installation of the Forward Abrasion Strips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 415
C. Removal of the Mid Abrasion Strips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 415
D. Installation of the Mid Abrasion Strips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 415
E. Removal of the Aft Abrasion Strips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 416
F. Installation of the Aft Abrasion Strips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 416
G. Removal of a Ground Handling Attach Point . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 416
H. Installation of a Ground Handling Attach Point . . . . . . . . . . . . . . . . . . . . . . . . . . . . 416
Inspection / Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601
1. Aft and Forward Saddle Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601
A. Inspections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601
Figure 601.Saddle Inspections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 602
Figure 602.Aft Side-Stop Clamp Inspections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 603
2. Aft LH and RH Side-Stop Clamp Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 603
A. Inspection of the Aft Clamp Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 603
3. Forward LH and RH Side-Stop Clamp Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . 604
A. Inspection of the Forward Clamp Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 604
Figure 603.Forward Side-Stop Clamp Inspections . . . . . . . . . . . . . . . . . . . . . . . . . 604
4. Inspections for the Standard Landing Gear Assembly . . . . . . . . . . . . . . . . . . . . . . . . . 605
A. Aft Crosstube Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 605
Table 601.Maximum Aft Crosstube Spread . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 605
Figure 604.Aft Crosstube Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 605
B. Forward Crosstube Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 606
Table 602.Maximum Forward Crosstube Spread . . . . . . . . . . . . . . . . . . . . . . . . . . 606
Page ii

Figure 605.Forward Crosstube Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 606
C. Forward Spacer Fitting Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 607
Figure 606.Forward Spacer Fitting Inspections . . . . . . . . . . . . . . . . . . . . . . . . . . . . 607
D. Fluid Level Check of the Landing Gear Damper Assemblies . . . . . . . . . . . . . . . . . 608
Figure 607.Damper Fluid Level Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 608
E. Landing Gear Damper Assembly Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 609
Figure 608.Damper Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 609
Figure 609.Skid Tube Inspections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 610
F. Skid Tube Assembly Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 611
Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 801
1. Landing Gear Damper Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 801
A. Drain Port Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 801
Figure 801.Location of Damper Drain Ports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 801
Figure 802.Skid Tube Repairable Sections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 802
2. Left-Hand and Right-Hand Skid Tube Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . 802
A. Blend Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 802
3. Nonslip Surfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 802
32-40-00 Ground Handling Wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A
1. Ground Handling Wheel Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
A. Description and Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
B. Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
C. Steel Rims . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
D. Main Frame Body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
E. Hydraulic Jack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
F. Attach Cradle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
Figure 201.Ground Handling Wheel Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
Page iii

Page iv
Section
320000
Landing Gear
Assembly
LANDING GEAR
1. Standard Landing Gear Assembly The aft crosstube is attached to the fuselage at
FS 233.0 and BL 23.25 by the aft saddle
A. Introduction assembly. The forward and aft crosstubes
provide elastic deformation during normal
The standard landing gear assembly (landing landings. The crosstubes provide energy
gear) supports the helicopter when it is in attenuation and permanent deformation
contact with the ground. The landing gear can during severe landings.
withstand loads made during landing, ground
handling, and provides a stable platform to C. Forward and Aft Saddle Assemblies
prevent ground resonance.
The forward and aft saddle assemblies are
The landing gear primarily absorbs normal 7050 T7451 aluminum alloy clamps that
landing forces, with the capabilities to absorb attach to the fuselage fittings. The clamp
severe landing forces during overload condi assemblies secure the forward and aft cross
tions. The landing gear dimensions are based tube assemblies to the exterior of the helicop
on the required minimum roll-over and ter.
minimum pitch-over angles. A minimum
angle of 27 degrees is maintained from the The saddle assemblies have elastomeric
center of gravity (CG) location to the skid-to- rubber pads installed between the clamp and
ground contact point. The landing gear has crosstube to decrease landing gear-to-ground
these components: resonance oscillations.
Forward and Aft Crosstubes - Provide D. Side Stop Clamp Assemblies

energy absorbing capabilities during normal
or severe landings. Side stop clamp assemblies are 7050 T7451
aluminum alloy clamps with nonsymmetrical
Forward and Aft Saddle Assemblies - flats. The clamp assemblies attach to each
Provide a means to attach the crosstube crosstube assembly immediately inboard of the
assemblies to the fuselage attachment forward and aft saddle assemblies.
points.
The side stop clamp assemblies prevent side
Side Stop Clamp Assemblies - Prevent movement of the crosstube during landing.
side movement of the crosstube assemblies. The clamp assembly uses a rubber pad
installed between the crosstube assembly and
Forward Spacer Fittings - Forward clamp to decrease ground resonance oscilla
attachments for the skid tubes and forward tions.
crosstube assembly.
A portion of the side stop clamps have metal to
Landing Gear Damper Assemblies - Aft metal contact with the crosstube assemblies. A
attachments for the skid tubes and aft bonding strap is secured from the clamps to
crosstube assembly. the fuselage attach fittings for lightning strike
protection.
Skid Tubes - Provide landing gear-to-
ground contact points. E. Forward Spacer Fittings
B. Forward and Aft Crosstubes The forward spacer fittings are 7075 T6
aluminum alloy spacers that attach to the
The forward and aft crosstubes are energy forward crosstube assembly and skid tubes.
absorbing tubes constructed from 7075 T6 The spacer fittings secure the skid tubes to the
aluminum alloy. The forward crosstube crosstube assembly. The spacer fittings
attaches to the fuselage at FS 154.0 and BL transfer landing loads from the skid tubes to
9.275 by the forward saddle assembly. the crosstube assemblies.
Page 1
F. Landing Gear Damper Assemblies The reservoir fluid level indicator (1) is a
rotating shaft which shows through a 120 pie
shaped window. When the reservoir is filled,
The landing gear damper assemblies are the window shows green with a very thin
bidirectional hydraulic units that attach to the wedge of red showing to the first notch (2) on
aft crosstube assembly and skid tubes. The the housing. The thin wedge of red shows the
damper assemblies secure the skid tubes to reservoir is not completely full, to allow for
the crosstube assembly while transferring fluid expansion.
landing loads from the skid tubes to the
crosstube assembly. The dampers also dissi G. Skid Tubes
pate landing gear-to-ground resonance
oscillations and absorb vertical shock loads The skid tubes are 7075 T6 aluminum alloy
during landings. tubes that are attached to the forward and aft
crosstube assemblies by the forward spacer
fittings and damper assemblies. The skid
Each damper is an aluminum alloy housing tubes provide a ground contact point for the
with an internal bidirectional hydraulic landing gear. Each skid tube has a forward,
metering circuit. The damping rate of the unit middle and aft steel abrasion strip that
is controlled by forcing fluid from one side of protects the skid tubes during landing.
the internal damper piston to the other side of
the internal piston head. An internal bidirec The middle of the skid provides a fixed
tional fixed orifice is housed in the piston head bushing/pin location for use of the ground
to meter the damping rate. The damper handling wheels during ground operations. A
incorporates an integral reservoir to supply crew station access step is located on the top of
compensation for thermal expansion and fluid each skid tube. The access step provides a 4 by
leakage. 8 inch (10 by 20 cm) non-slip step area.
SIDE STOP
CLAMP ASSEMBLY
AFT
CROSSTUBE
PLUG
AFT AFT
ABRASION STRIP SADDLE ASSEMBLY
FORWARD DAMPER
CROSSTUBE ASSEMBLY
FORWARD FORWARD
FORWARD SADDLE ASSEMBLY SPACER FITTING
ABRASION STRIP
GROUND HANDLING
STEP ATTACH POINTS
MID ABRASION
STRIP
SKID TUBE
9G32-001
Figure 1. Landing Gear Assembly
Page 2
LANDING GEAR
FAULT ISOLATION
1. Standard Landing Gear Assembly
Troubleshooting
The troubleshooting procedures of Table 101
are a brief summary of landing gear system
faults that can occur.
Table 101. Standard Landing Gear Assembly Troubleshooting
Unusual or too much Damper damage Examine saddle pads, side 320000
vibration Saddle assembly pad stop clamp pads, and/or
damage landing gear damper
assemblies
Side stop clamp pad
damage
Incorrect ground attitude Crosstube damage Examine forward and aft 320000
crosstubes
Landing gear damper Fluid level low Examine fluid level and fill 320000 &
assembly low Damper damage damper with fluid, if necessary 120000
Examine dampers 320000
Page 101
Page 102
LANDING GEAR
1. Forward LH and RH Side StopClamp contact surface of forward crosstube (3)
Assemblies (ref. CSP-SPM, Section 20-20-00).
A. Removal of the Forward StopClamps (2). Install forward stop-clamp (1) on

forward crosstube (3).
(Ref. Figure 401)
(a). Align round-end bolt (6) with com
NOTE: This task is typical for the LH or RH pression pad (7).
forward stop-clamp assemblies.
(b). Install countersunk washer (9) on
(1). Carefully loosen jam nut (4) and bolt (10).
round-end bolt (6) sufficiently to
disengage from and not touch compres Make sure countersunk washer
CAUTION (9) is next to head of bolt (10) be
sion pad (7) of fuselage fitting (8).
fore you install jumper (2). Incorrect assem
Sealing Compound (C211) bly can cause electrical problems.
(c). Install jumper (2) on bolt (10).
(d). Install jumper (2), countersunk
washer (9), and bolt (10) in forward
(2). Remove sealing compound (C211) from stop-clamp (1) with flat washer (11)
head of bolt (10). and nut (12).
(3). Remove nut (12), washers (9, 11), the (e). Torque nut (12) 70 to 90 in-lb (7.91
end of jumper (2), and bolt (10) from to 10.17 Nm) more than the run-on
forward stop-clamp (1). torque (ref. CSP-SPM, Section
20-10-10)..
(4). Open forward stop-clamp (1) to remove
from forward crosstube (3). Sealing Compound (C211)
(5). Remove sealing compound (C211) from

parts (ref. CSP-SPM, Section
20-20-00).
B. Installation of the Forward StopClamps (f). Environmentally seal jumper connec

tion and perimeter of forward stop-
(Ref. Figure 401) clamp with sealing compound (C211)
(ref. CSP-SPM, Section 20-50-00).
NOTE: This task is typical for the LH or RH
forward stop-clamp assemblies. (3). Slowly install round-end bolt (6)
through forward stop-clamp (1) until
bolt (6) touches compression pad (7).
(Ref. CSPSPM) (4). After the initial touch, tighten round-
Item Nomenclature end bolt (6) an additional 2.67 turns.
C211 Sealing Compound, Corrosion Inhibitive NOTE: This will result in a 0.095 compression
C225 Sealing and Locking Compound of the elastomer pad of the compression pad
(7).
(1). Prepare forward stop-clamp (1) and (5). Tighten jam nut (4) to lock round-end
jumper (2) for an electrical bond to the bolt (6).
Page 401
Sealing and Locking Compound (C225)
(6). Apply sealing and locking compound

(C225) to jam nut (4), flat washer (5),
and round-end bolt (6).
REF.
ENVIRONMENTAL
SEALING COMPOUND
8
7 8
5
4
6
9 10
11
12
RIGHT SIDE SHOWN

LEFT SIDE TYPICAL
2
9G32-027
1. FORWARD STOPCLAMP (REF. IPL, 320000, FIG. 1) 7. COMPRESSION PAD (REF. IPL, 320000, FIG. 1)
2. JUMPER 8. FUSELAGE FITTING (NO IPL REF.)
3. FORWARD CROSSTUBE 9. COUNTERSUNK WASHER (REF. IPL, 320000, FIG. 1)
4. JAM NUT (REF. IPL, 320000, FIG. 7) 10. BOLT
5. FLAT WASHER 11. FLAT WASHER
6. ROUNDEND BOLT 12. NUT
Figure 401. Removal and Installation of the Forward StopClamps
Page 402
Page 403
2
1
RIGHT SIDE SHOWN
LEFT SIDE TYPICAL 2
REF.
ENVIRONMENTAL
SEALING
COMPOUND
14
14
AFT, 7 TO 13
9 (REF) CLEARANCE
2 (REF)
13 6 2 (REF)
9
8 (REF)
11
12
4
7 10
4
6
LEFT SIDE SHOWN,
5 RIGHT SIDE TYPICAL.
9G32-030
1. AFT CROSSTUBE (REF. IPL, 320000, FIG. 1) 8. AFT STOPCLAMP
2. FUSELAGE FITTING (NO IPL REF.) 9. PAD (REF. IPL, 320000, FIG. 6)
3. BRACKET 10. BOLT (REF. IPL, 320000, FIG. 1)
4. JUMPER (REF. IPL, 320000, FIG. 1) 11. COUNTERSUNK WASHER
5. BOLT 12. FLAT WASHER
6. WASHER 13. NUT
7. NUT 14. SKID TUBE ASSEMBLY
Figure 402. Removal and Installation of the Aft StopClamps
Page 404
2. Landing Gear (Aft) LH and RH Side (1). Prepare the mating surfaces of aft
StopClamp Assemblies stop-clamp (8), end of jumper (4), and
aft crosstube (1) for an electrical bond
A. Removal of the Aft StopClamps (ref. CSP-SPM, Section 20-50-00).
(Ref. Figure 402)
Make sure countersunk washer
CAUTION
NOTE: This task is typical for the LH or RH aft (11) is next to head of bolt (10)
stop-clamp assemblies. before you install jumper (4). Incorrect as
sembly can cause electrical problems.
(2). Install aft stop-clamp (8) on aft
crosstube (1) with bolt (10), counter
sunk washer (11), the end of jumper (4),
flat washer (12), and nut (13).
(1). Remove sealing compound (C211) from
head of bolt (10). (3). Turn aft stop-clamp (8) 7 to 13 de
grees aft from the 12 o'clock position.
(2). Remove bolt (10), countersunk washer
(11), the end of jumper (4), flat washer (4). Make sure there is a 0.06 inch (1.5
(12), and nut (13). mm) clearance between fuselage
fitting (2) and pad (9) of aft stop-clamp
(3). Let jumper (4) hang loose until installa (8).
tion.
(5). Torque nut (13) 70 to 90 in-lb (7.91 to
(4). Open aft stop-clamp (8) to remove from 10.17 Nm) more than the run-on
aft crosstube (1). torque (ref. CSP-SPM, Section
B. Installation of the Aft StopClamps 20-10-10).

NOTE: This task is typical for the LH or RH aft
stop-clamp assemblies.
Consumable Materials (6). Environmentally seal the connection of

(Ref. CSPSPM) jumper (4) and the perimeter of aft
Item Nomenclature stop-clamp (8) with sealing compound
C211 Sealing Compound, Corrosion Inhibitive (C211) (ref. CSP-SPM, Section
20-50-00).
Page 405
2
4
3
1
10 8
9 6 (REF)
7 21
4 (REF)
5 (REF)
21
16
14
14
2 (REF) 20
12
13
12
15
18
18
17
20 (REF)
16 (REF) 17 19
19
REF. ENVIRONMENTAL
REF. ENVIRONMENTAL SEALING COMPOUND
SEALING COMPOUND
LEFT SIDE SHOWN.
LEFT SIDE SHOWN. RIGHT SIDE TYPICAL.
RIGHT SIDE TYPICAL.
9G32-007-1D
Figure 403. Removal and Installation of the Landing Gear Assembly
Page 406

1. LANDING GEAR ASSY (REF. IPL, 320000, FIG. 2) 12. COUNTERSUNK WASHER
2. AFT CROSSTUBE 13. JUMPER
3. DAMPER ASSEMBLY 14. FLAT WASHER
4. AFT FUSELAGE FITTING (NO IPL REF.) 15. BOLT
5. FORWARD CROSSTUBE (REF. IPL, 320000, FIG. 2) 16. FORWARD SADDLE
6. FORWARD FUSELAGE FITTING (NO IPL REF.) 17. COUNTERSUNK WASHER
7. FORWARD STOPCLAMP (REF. IPL, 320000, FIG. 1) 18. FLAT WASHER
8. JAM NUT (REF. IPL, 320000, FIG. 7) 19. BOLT
9. FLAT WASHER 20. AFT SADDLE
10. ROUNDEND BOLT 21. SADDLE PAD
11. COMPRESSION PAD (REF. IPL, 320000, FIG. 1)
3. Standard Landing Gear Assembly B. Installation of the Landing Gear

Assembly
A. Removal of the Landing Gear Assembly
(Ref. Figure 403)
(Ref. Figure 403)
Hoisting (Ref. CSPSPM)
Item Nomenclature
C211 Sealing Compound, Corrosion Inhibitive
C225 Sealing and Locking Compound
(1). Hoist the rotorcraft until damper (1). Prepare the mating surfaces of aft and
assemblies (3) are extended (ref. forward saddle assemblies (4, 6), ends
Section 07-10-00). of jumpers (13), and aft and forward
crosstubes (2, 5) for an electrical bond
Make sure you support the land (ref. CSP-SPM, Section 20-50-00).
CAUTION ing gear assembly with jacks
during removal. Damage to components can (2). Put landing gear assembly (1) under
occur. rotorcraft.
NOTE: Use jacks and/or blocks to help center
(2). Carefully loosen jam nut (8) and the landing gear assembly and to keep the
round-end bolt (10) sufficiently to saddles parallel to the fittings.
disengage from and not touch compres
sion pad (11) of fuselage fitting (6). (a). Align saddle pads (21) on aft saddles
(20) and forward saddles (16) with aft
NOTE: If necessary, remove forward side- fuselage fittings (4) and forward
clamps (ref. Procedure 1.A.). fuselage fittings (6).
(3). Remove bolts (15), flat washers (14), (3). Lower the rotorcraft until aft and
ends of jumpers (13), countersunk forward fuselage fittings (4, 6) meet aft
washers (12), and forward saddles (16) and forward saddles (16, 20).
from forward fuselage fittings (6). (4). Install countersunk washers (17), flat
washers (18), bolts (19), and aft saddles
(4). Remove bolts (19), flat washers (18), (20) on aft fuselage fittings (4).
countersunk washers (17), and aft
saddles (20) from aft fuselage fittings (a). Torque bolts (19) 300 to 430 in-lb
(4). (33.90 to 48.58 Nm) more than the
run-on torque (ref. CSP-SPM,
(5). Remove landing gear assembly (1). Section 20-10-10).
Page 407

(Ref. CSPSPM)
Item Nomenclature
(5). Environmentally seal the connections
aft saddles (20) with sealing compound
(1). Install countersunk washers (17), flat
washers (18), bolts (19), and aft saddles
20-50-00).
(20) on aft fuselage fitting (4).
NOTE: If necessary, install forward side- (a). Torque bolts (19) 300 to 430 in-lb
clamps (7) (ref. Procedure 1.B.). (33.90 to 48.58 Nm) more than the
(6). Slowly install round-end bolt (10) run-on torque (ref. CSP-SPM,
through forward stop-clamp (7) until Section 20-10-10).
bolt (10) touches compression pad (11). Sealing Compound (C211)
(7). After the initial touch, tighten round-
end bolt (10) an additional 2.67 turns.
NOTE: This will result in a 0.095 compression
of the elastomer pad of the compression pad (2). Environmentally seal the seam be
(11). tween aft saddle (20), aft fuselage
fitting (4), and aft crosstube (2) with
(8). Tighten jam nut (8) to lock round-end
sealing compound (C211) (ref. CSP-
bolt (10).
SPM, Section 20-50-00).
5. LH and RH Forward Saddle Assemblies
A. Removal of the Forward Saddles
(Ref. Figure 403)
(9). Apply sealing and locking compound NOTE: This task is typical for the LH or RH
(C225) to jam nut (8), flat washer (9), forward saddle assemblies.
and round-end bolt (10).
(10). Lower the rotorcraft (ref. Section
07-10-00).
4. Aft LH and RH Saddle Assemblies
A. Removal of the Aft Saddles (1). Remove sealing compound (C211) from
head of bolt (15).
(Ref. Figure 403)
(2). Remove bolts (15), countersunk
NOTE: This task is typical for the aft LH or RH washers (12), the end of jumper (13),
saddle assemblies. flat washers (14), and forward saddle
(16) from forward fuselage fitting (6).
(1). Remove bolts (19), washers (17, 18),
and aft saddle (20) from aft fuselage (3). Let jumper (13) hang loose until
fitting (4). installation.
B. Installation of the Aft Saddles B. Installation of the Forward Saddles
NOTE: This task is typical for the aft LH or RH NOTE: This task is typical for the LH or RH
saddle assemblies. forward saddle assemblies.
Page 408
B. Installation of the Saddle Pads

(Ref. Figure 403)
(Ref. CSPSPM)
Item Nomenclature
C211 Sealing Compound, Corrosion Inhibitive (Ref. CSPSPM)
Item Nomenclature
C233 Chemical Coating
(1). Install countersunk washers (12), the
end of jumper (13), flat washers (14), C411 Adhesive, Epoxy
bolts (15), and forward saddle (16) on C802 Cloth, NonLint
forward fuselage fitting (6). C817 Pad, Scouring, Cellulose/Nylon
(a). Torque bolts (15) 130 to 180 in-lb (1). Scuff sand mating surfaces of saddle
(14.69 to 20.34 Nm) more than the pad (21) and fuselage fitting (4, 6) or
run-on torque (ref. CSP-SPM, saddle (16, 20) with a scouring pad
Section 20-10-10). (C817).
Chemical Coating (C233)
(2). Apply chemical coating (C233) to bare

aluminum.
(2). Environmentally seal the connection of
jumper (13) and the seam between Solvent Cleaner (C429)
forward saddle (16), forward fuselage
fitting (6), and forward crosstube (5)
with sealing compound (C211) (ref.
(3). Wipe the mating bond surfaces with
solvent cleaner (C429) and a non-lint
6. Landing Gear Saddle Pads
cloth (C802).
A. Removal of the Saddle Pads (a). Let the surfaces air-dry for 15
minutes minimum.
(Ref. Figure 403) Adhesive, Epoxy (C411)
NOTE: This task is typical at 8 locations.
(1). To remove a saddle pad (21) from a

fuselage fitting (4, 6), remove landing (4). Apply epoxy adhesive (C411)to mating
gear assembly (1) (ref. Procedure 3.A.). surface.
(5). Install saddle pad (21) on fuselage
(2). To remove a saddle pad (21) from a aft fitting (4, 6) or saddle (16, 20).
saddle (20) or forward saddle (16),
remove the applicable saddle (ref. NOTE: If the saddle pad is replaced in a fuse
Procedure 4.A. or Procedure 5.A., lage fitting, use a cylindrical or tubular
respectively). piece of aluminum, or other suitable materi
al, with an approximate 2.40 inch (61.0
(3). Remove saddle pad (21) from fuselage mm) diameter, to hold the pad in place
during the epoxy cure.
fitting (4, 6) or saddle (16, 20).
(6). Let the epoxy cure for 24 hours at
(4). Remove the remaining epoxy adhesive room temperature or 2 hours at 150
(C411). to 170F (66 to 77C).
Page 409
(7). Trim pad flush +0.060 inch (1.52 mm) assembly (ref. Procedure 3.B.), aft
/ -0.000 inch (0.00 mm). saddle (ref. Procedure 4.B.), or forward
(8). As necessary, install landing gear saddle (ref. Procedure 5.B.).
1
2
6 2
5
5 (REF)
8 6 (REF)
7 9
10
11 12 1 (REF)
14
2 (REF)
13
3 (REF)
15 18
17
16 DRAIN PORTS (BOTH SIDES)
LEFT SIDE SHOWN,
RIGHT SIDE TYPICAL.
3 (REF)
19 20
LEFT SIDE SHOWN.

RIGHT SIDE TYPICAL
9G32-031A
1. AFT CROSSTUBE (REF. IPL, 320000, FIG. 2) 11. FLAT WASHER

2. DAMPER ASSEMBLY 12. BOLT
3. LH SKID TUBE 13. COUNTERSUNK WASHER
4. RH SKID TUBE 14. BOLT
5. FORWARD CROSSTUBE 15. FLAT WASHER
6. FORWARD SPACER FITTING 16. NUT
7. COUNTERSUNK WASHER 17. COUNTERSUNK WASHER
8. BOLT 18. BOLT
10. NUT 20. BOLT
Figure 404. Assembly and Disassembly of the Landing Gear Assembly
Page 410
7. Assembly and Disassembly of the (3). Attach forward spacer fitting (6) to
Standard Landing Gear Assembly forward crosstube (5) with countersunk
washers (7), bolts (8), flat washers (9),
A. Removal of the Forward Spacer Fittings and nuts (10).
(Ref. Figure 404) (4). Attach forward spacer fitting (6) to skid
tubes (3, 4) with washers (11) and bolts
NOTE: This task is typical for the left or right (12).
forward spacer fittings.
Jacking
(5). Environmentally seal all external

(1). If necessary, jack the rotorcraft until mating parts with sealing compound
skid tubes (3, 4) clear the ground (ref. (C211) (ref. CSP-SPM, Section
Section 07-10-00). 20-50-00).
(2). Remove sealant from heads of bolts (8, (6). Lower the rotorcraft (ref. Section
12). 07-10-00).
C. Removal of the Damper Assemblies
(3). Remove nuts (10), flat washers (9),
countersunk washers (7), and bolts (8). (Ref. Figure 404)
(4). Remove bolts (12) and washers (11). NOTE: This task is typical for the left or right
damper assembly.
(5). Remove forward spacer fitting (6).
Jacking
B. Installation of the Forward Spacer
Fittings
(Ref. Figure 404)
NOTE: This task is typical for the left or right (1). If necessary, jack the rotorcraft until
forward spacer fittings. skid tubes (3, 4) clear the ground (ref.
Section 07-10-00).
Consumable Materials (2). Remove sealant from heads of bolts (14,

(Ref. CSPSPM) 18, 20).
Item Nomenclature
(3). Remove bolts (14), countersunk
C211 Sealing Compound, Corrosion Inhibitive washers (13), flat washers (15), and
nuts (16).
Jacking (4). Remove lockwire from bolts (18).
(1). If necessary, jack the rotorcraft until (7). Remove damper assembly (2).
skid tubes (3, 4) clear the ground (ref. D. Installation of the Damper Assemblies
Section 07-10-00).
(Ref. Figure 404)
(2). Align the bolt holes of forward spacer
fitting (6), skid tubes (3, 4), and forward NOTE: This task is typical for the left or right
crosstube (5). damper assembly.
Page 411
Jacking
(Ref. CSPSPM)
Item Nomenclature
C702 Lockwire (1). Jack the rotorcraft until damper
assemblies (2) are fully extended (ref.
Section 07-10-00).
(1). Align the bolt holes of damper assembly
(2) and aft crosstube (1). (2). Remove sealing compound (C211) from
heads of bolts (12, 20).
(2). Install countersunk washers (13), bolts
(14), flat washers (15), and nuts (16). (3). Remove bolts (12) and washers (11)
from forward fitting spacer (6) and skid
(3). Install countersunk washers (17) and tube (3 or 4).
bolts (18). (4). Remove bolts (20) and washers (19)
(a). Torque bolts (18) 100 to 140 in-lb from dampers (2) and skid tube (3 or 4).
(11.30 to 15.82 Nm). F. Installation of the Skid Tube Assemblies
(b). Safety bolts (18) with lockwire (Ref. Figure 404)
(C702).
NOTE: This task is typical for the LH or RH
(4). Attach damper assembly (2) to skid skid tube assemblies.
tube assembly (3 or 4) with washers
(19) and bolts (20). Consumable Materials
(5). Apply masking tape to drain ports of (Ref. CSPSPM)
damper assembly (2). Item Nomenclature
(1). Put skid tube (3 or 4) in position.
(a). Align skid tube (3 or 4) with forward
spacer fitting (6) and damper assem
Do not put sealing compound bly (2).
CAUTION (C211) in the drain ports of
damper assemblies (2). Blocked drain ports (2). Attach skid tube (3 or 4) to damper
can cause internal corrosion in damper as assembly (2) with washers (19) and
semblies (2). bolts (20).
(3). Attach skid tube (3 or 4) to forward
(6). Environmentally seal all external spacer fitting (6) with washers (11) and
mating parts with sealing compound bolts (12).
20-50-00). Sealing Compound (C211)
(7). Remove masking tape.
(8). Lower the rotorcraft (ref. Section
07-10-00).
(4). Environmentally seal all external
E. Removal of the Skid Tube Assemblies mating parts with sealing compound
(Ref. Figure 404) 20-50-00).
NOTE: This task is typical for the LH or RH (5). Lower the rotorcraft (ref. Section
skid tube assemblies. 07-10-00).
Page 412
G. Removal of the Aft Crosstube I. Removal of the Forward Crosstube

(Ref. Figure 404)
(Ref. Figure 404)
NOTE: The landing gear assembly must be re
moved before the removal of the aft cross
NOTE: The landing gear assembly must be re
tube (ref. Procedure 3.A.).
moved before the removal of the forward
(1). Remove sealant from heads of bolts (14, crosstube (ref. Procedure 3.A.).
18).
(2). Remove lockwire from bolts (18). (1). Remove sealant from heads of bolts (8).
(3). Remove bolts (14, 18), washers (13, 15, (2). Remove bolts (8), countersunk washers
17), and nuts (16) from damper assem (7), flat washers (9), and nuts (10) from
blies (2) and aft crosstube (1). forward spacer fittings (6) and forward
(4). Remove aft crosstube (1). crosstube (5).
H. Installation of the Aft Crosstube (3). Remove forward crosstube (5) from
(Ref. Figure 404) forward spacer fittings (6).
Consumable Materials J. Installation of the Forward Crosstube

(Ref. CSPSPM)
C702 Lockwire
(Ref. CSPSPM)
(1). Align the bolt holes of aft crosstube (1) Item Nomenclature
and damper assemblies (2).
(2). Install countersunk washers (13), bolts
(14), flat washers (15), and nuts (16).
(3). Install countersunk washers (17) and (1). Align the bolt holes of forward cross
tube (5) and forward spacer fittings (6).
bolts (18).
(a). Torque bolts (18) 100 to 140 in-lb (2). Install countersunk washers (7), bolts
(11.30 to 15.82 Nm). (8), flat washers (9), and nuts (10).
(b). Safety bolts (18) with lockwire
(C702). Sealing Compound (C211)
(4). Environmentally seal all external (3). Environmentally seal all external
mating parts with sealing compound mating parts with sealing compound
(C211) (ref. CSP-SPM, Section (C211) (ref. CSP-SPM, Section
20-50-00). 20-50-00).
Page 413
LEFT SIDE SHOWN,

RIGHT SIDE TYPICAL
13 12 11
4 PL
10
8 9
8
8 9
4 3 8
7
2
6 PL
10
8 9
10 9 8
8
7
8
6
10 5
8
9
98
7
9G32-007-3B
1. SKID TUBE (REF. IPL, 320000, FIG. 3) 8. WASHER

2. FORWARD ABRASION STRIP 9. SLEEVE SPACER
3. WASHER 10. NUT
4. SCREW 11. AFT ABRASION STRIP
5. MID ABRASION STRIP 12. WASHER
6. BOLT 13. SCREW
7. BOLT
Figure 405. Skid Tube Assemblies
Page 414
8. Assembly and Disassembly of the LH and (3). If necessary, lower the rotorcraft (ref.
RH Skid Tube Assemblies Section 07-10-00).
A. Removal of the Forward Abrasion Strips C. Removal of the Mid Abrasion Strips
NOTE: This task is typical for the left or right NOTE: This task is typical for the mid abrasion
forward abrasion strips. strips on either the LH or RH skid tube as
semblies.
Jacking
Jacking
(1). If necessary, jack the rotorcraft until

skid tubes (3, 4) clear the ground (ref. (1). If necessary, jack helicopter until skid
Section 07-10-00). tubes (3, 4) clear the ground (ref.
Section 07-10-00).
(2). Remove sealant from heads of screws
(2). Remove sealant from heads of bolts (6,
(4).
7).
(3). Remove nut (10), bolt (6), and washers
forward abrasion strip (2).
(8).
B. Installation of the Forward Abrasion (4). Remove nut (10), bolt (7), washers (8),
Strips spacers (9), and mid abrasion strip (5).
(Ref. Figure 405) D. Installation of the Mid Abrasion Strips
NOTE: This task is typical for the left or right (Ref. Figure 405)
forward abrasion strips.
NOTE: This task is typical for the mid abrasion
strips on either the LH or RH skid tube as
semblies.
(Ref. CSPSPM)
Item Nomenclature
C213 Sealing Compound, Corrosion Inhibitive Consumable Materials
(Ref. CSPSPM)
Item Nomenclature
(1). Install forward abrasion strips (2) with C213 Sealing Compound, Corrosion Inhibitive
washers (3) and screws (4).
(a). Torque screws (4) (ref. CSP-SPM, (1). Install mid abrasion strips (5) with
20-10-00). bolts (6, 7), washers (8), spacers (9),
and nuts (10).
(a). Torque bolts (6, 7) and nuts (10) (ref.
(2). Install mid abrasion strips (5) with
bolts (7), washers (8), spacers (9), and
(2). Install a fillet seal around all external nuts (10).
mating parts and fasteners with sealing
compound (C213) (ref. CSP-SPM, (a). Torque bolts (7) and nuts (10) (ref.
Section 20-50-00). CSP-SPM, 20-10-00).
Page 415
Sealing Compound (C213) Sealing Compound (C213)
(2). Install a fillet seal around all external

(3). Install a fillet seal around all external mating parts and fasteners with sealing
mating parts and fasteners with sealing compound (C213) (ref. CSP-SPM,
compound (C213) (ref. CSP-SPM, Section 20-50-00).
Section 20-50-00).
(3). If necessary, lower the rotorcraft (ref.
Section 07-10-00).
(4). If necessary, lower the rotorcraft (ref.
Section 07-10-00). G. Removal of a Ground Handling Attach
Point
E. Removal of the Aft Abrasion Strips (Ref. Figure 405)
(Ref. Figure 405) NOTE: This task is typical for each ground
handling attach point on either the LH or
RH skid tube assemblies.
NOTE: This task is typical for the aft abrasion
strips on either the LH or RH skid tube as (1). Remove sealant from the head of bolt
semblies. (7).
(2). Remove nut (10), bolt (7), washers (8),
Jacking
and spacers (9).
H. Installation of a Ground Handling Attach
Point
(Ref. Figure 405)
(1). If necessary, jack the rotorcraft until NOTE: This task is typical for each ground
skid tubes (3, 4) clear the ground (ref. handling attach point on either the LH or
Section 07-10-00). RH skid tube assemblies.
(2). Remove sealant from heads of screws Consumable Materials

(13). (Ref. CSPSPM)
Item Nomenclature
(3). Remove screws (13), washers (12), and C213 Sealing Compound, Corrosion Inhibitive
aft abrasion strip (11).
F. Installation of the Aft Abrasion Strips (1). Install bolt (7), washers (8), spacers (9),
and nut (10).
(Ref. Figure 405) (a). Torque bolt (7) and nut (10) (ref.
NOTE: This task is typical for the aft abrasion Sealing Compound (C213)
strips on either the LH or RH skid tube as
semblies.
(1). Install aft abrasion strip (11) with

washers (12) and screws (13). (2). Install a fillet seal around all external
mating parts and fasteners with sealing
(a). Torque screws (13) (ref. CSP-SPM, compound (C213) (ref. CSP-SPM,
Section 20-10-00), Section 20-50-00).
Page 416
LANDING GEAR
INSPECTION / TEST
1. Aft and Forward Saddle Assemblies (a). No damage, deformation, or corrosion
permitted.
NOTE: If the optional cargo hook is used, there
is an additional inspection for the aft saddle (5). Examine forward and aft saddle
assemblies (ref. Section 25-55-00, Inspec bushing holes for damage, deformation,
tion / Check, Aft Saddle Clamp Inspection). and corrosion.
A. Inspections (a). No damage, deformation, or corrosion
(Ref. Figure 601) permitted.
(1). Examine saddle clamps (3, 10) for (6). Examine saddle pads (7, 15) for
missing bolts (4, 11) and washers (5, 6, deterioration, protrusions, and tears.
12, 14). (a). No deterioration, protrusions, or
(a). Replace missing bolts (4, 11) and tears permitted.
washers (5, 6, 12, 14).
(7). Examine saddle pads (7, 15) bonded to
(2). Remove saddle (3, 10) (ref. 32-00-00, saddle assemblies (3, 10) for wear.
Landing Gear Assembly Removal).
NOTE: Bonded saddle pads (7, 15) are trimmed
(3). Examine saddle (3, 10) for cracks, flush, or 0.06 inch (1.5 mm) maximum to
dents, gouges, and corrosion. flat surface on fuselage fittings (2, 9) and
saddle assemblies (3, 10).
(a). No cracks, dents, gouges, or corrosion
permitted. (a). No wear permitted.
(4). Examine forward and aft saddle (8). Examine saddle pad bonds for cracks.
fastener holes for damage, deformation,
and corrosion. (a). No cracks permitted.
Page 601
9
7
REF. 3 1
15
3
15 REF. ENVIRONMENTAL
SEALING COMPOUND 6
13 10 5
14 14
4
12
11 8
12
11
LEFT SIDE SHOWN, REF. 10

RIGHT SIDE TYPICAL.
REF. ENVIRONMENTAL
SEALING COMPOUND 9G32-022C
1. AFT CROSSTUBE 9. FORWARD FUSELAGE FITTING
2. AFT FUSELAGE FITTING 10. FORWARD SADDLE
3. AFT SADDLE 11. BOLT
4. BOLT 12. COUNTERSUNK WASHER
5. COUNTERSUNK WASHER 13. JUMPER
7. SADDLE PAD 15. SADDLE PAD
8. FORWARD CROSSTUBE
Figure 601. Saddle Inspections
Page 602
13
RIGHT SIDE SHOWN

LEFT SIDE TYPICAL
REF.
ENVIRONMENTAL
SEALING 4
COMPOUND
1 12
8 14
5 6
2
11
9
3
9
10
9G32-029
1. SIDESTOP CLAMP 8. NUT
2. JUMPER 9. FLAT WASHER
3. BRACKET 10. SCREW
4. AFT CROSSTUBE 11. NUT
5. COUNTERSUNK WASHER 12. PAD
6. BOLT 13. FUSELAGE FITTING
7. FLAT WASHER 14. AFT SADDLE
Figure 602. Aft SideStop Clamp Inspections
2. Aft LH and RH SideStop Clamp (4). Examine environmental sealing
Assemblies compound of jumper (2) terminals for
cracks.
A. Inspection of the Aft Clamp Assemblies
(Ref. Figure 602)
(5). Examine jumper (2) bolt holes for
(1). Examine side-stop clamps (1) for damage, deformation, and corrosion.
cracks, dents, gouges, and corrosion.
(a). No damage, deformation, or corrosion
(a). No cracks, dents, gouges, or corrosion permitted.
permitted. (6). Remove side stop clamps (1) (ref.
Section 32-00-00, Removal/Installa
(2). Examine side-stop clamps (1) for
tion).
missing bolts (6), washers (5, 7), and
nuts (8). (7). Examine dowel pin hole for damage,
deformation, and corrosion.
(a). Replace missing bolts (6), washers (5,
7), and nuts (8). (a). No damage, deformation, or corrosion
permitted.
(3). Examine jumpers (2) for corrosion.
(8). Examine clamp pad (12) for cuts,
(a). No corrosion permitted. deterioration, or protrusion.
Page 603
(a). No cuts, deterioration, or protrusion (3). Examine jumpers (2) for corrosion.
permitted.
(a). No corrosion permitted.
3. Forward LH and RH SideStop Clamp (4). Examine environmental sealing
Assemblies compound of jumper (2) terminals for
cracks.
A. Inspection of the Forward Clamp
Assemblies (a). No cracks permitted.
(Ref. Figure 603) (5). Examine jumper (2) bolt holes for
damage, deformation, and corrosion.
corrosion, cracks, dents, and gouges. (a). No damage, deformation, or corrosion
permitted.
(a). No corrosion, cracks, dents, or gouges (6). Remove side-stop clamps (2) (ref.
permitted. Section 32-00-00, Removal/Installa
tion).
missing nuts (4, 12), washers (5, 9, 11), (7). Examine dowel pin (7) hole for damage,
and bolts (6, 10). deformation, and corrosion.
(a). Replace missing nuts (4, 12), washers (a). No damage, deformation, or corrosion
(5, 9, 11), and bolts (6, 10). permitted.
REF.
ENVIRONMENTAL
SEALING COMPOUND
8
8 (REF)
5
4
6
7
9 10
11
12
RIGHT SIDE SHOWN

LEFT SIDE TYPICAL
2
9G32-028
1. SIDESTOP CLAMP 7. DOWEL PIN
2. JUMPER 8. FUSELAGE FITTING
3. FORWARD CROSSTUBE 9. FLAT WASHER
4. JAM NUT 10. BOLT
6. ROUNDEND BOLT 12. NUT
Figure 603. Forward SideStop Clamp Inspections
Page 604
4. Inspections for the Standard Landing (a). No damage, deformation, or corrosion

Gear Assembly permitted.
A. Aft Crosstube Inspection (4). Jack helicopter (ref. Section 07-10-00).
(Ref. Figure 604)
(5). Measure the spread of the aft crosstube
The aft crosstube must be re from the outside edge of one skid tube
CAUTION placed when there has been per
to the outside edge of the opposite skid
manent deformation to the point where it is tube at the aft face of the skid tubes.
no longer safe to fly. The change in spread
between the skid tubes is the criteria for re (a). Nominal unloaded measurement is
placement. 91.50 inch (232.41 cm).
(1). Examine the aft crosstube for cracks,
dents, gouges, and corrosion. (b). If the measurement is more than the
maximum spread (ref. Table 601),
(a). No cracks, dents, gouges, or corrosion replace the aft crosstube.
permitted.
(2). Examine the aft crosstube for indica Table 601. Maximum Aft Crosstube Spread
tions of contact with the fuselage Gross Weight
fittings and the aft saddle assemblies. During Operation Maximum Spread
(a). If there are indications of contact, 6000 lb (2721.6 kg) 95.60 inch (242.82 cm)
replace the aft crosstube.
6250 lb (2835.0 kg) 95.00 inch (241.30 cm)
(3). Examine the aft crosstube bolt holes for
damage, deformation, and corrosion. 6500 lb (2948.4 kg) 94.41 inch (239.80 cm)
2.2495
2.2390
91.50 inches NOMINAL

232.41 cm
9G32-020B
Figure 604. Aft Crosstube Measurement
Page 605
B. Forward Crosstube Inspection (a). No damage, deformation, or corrosion

permitted.
(Ref. Figure 605)
(4). Jack helicopter (ref. Section 07-10-00).
The forward crosstube must be
CAUTION replaced when there has been (5). Measure the spread of the forward
permanent deformation to the point where crosstube from the outside face of the
it is no longer safe to fly. The change in gusset flange on the left spacer to the
spread between the skid tubes is the criteria outside face of the gusset flange on the
for replacement. right spacer.
(1). Examine the forward crosstube for (a). Nominal unloaded measurement is
cracks, dents, gouges, and corrosion. 88.30 inch (224.28 cm).
(a). No cracks, dents, gouges, or corrosion (b). If the measurement is more than the
permitted. maximum spread (ref. Table 602),
replace the forward crosstube.
(2). Examine the forward crosstube for
indications of contact with the fuselage Table 602. Maximum Forward Crosstube Spread
fittings or the front saddle assemblies.
Gross Weight
(a). If there are indications of contact, During Operation Maximum Spread
replace the forward crosstube. 6000 lb (2721.6 kg) 89.60 inch (227.58 cm)
(3). Examine the forward crosstube bolt 6250 lb (2835.0 kg) 89.25 inch (226.69 cm)
holes for damage, deformation, and
corrosion. 6500 lb (2948.4 kg) 88.91 inch (225.83 cm)
88.30 inches NOMINAL

224.28 cm
9G32-019C
Figure 605. Forward Crosstube Measurement
Page 606
C. Forward Spacer Fitting Inspection (9) for damage, deformation, and

corrosion.
(Ref. Figure 606)
(1). Examine forward spacer fitting (1) for permitted.
cracks, dents, gouges, and corrosion.
(4). Examine bolt (3) holes of forward
spacer fitting (1) and forward crosstube
(9) for damage, deformation, and
permitted.
corrosion.
(2). Examine forward spacer fitting (1) for (a). No damage, deformation, or corrosion
missing nuts (5), bolts (3, 7), and permitted.
washers (2, 4, 6).
(5). Examine bolt (7) holes of forward
(a). Replace missing nuts (5), bolts (3, 7), spacer fitting (1) and skid tube (8) for
and washers (2, 4, 6). damage, deformation, and corrosion.
(3). Examine mating surfaces of forward (a). No damage, deformation, or corrosion

spacer fitting (1) to forward crosstube permitted.
LEFT SIDE SHOWN,

RIGHT SIDE TYPICAL.
1
3
4
2 5
6 7
9G32-021A
1. FORWARD SPACER FITTING 6. FLAT WASHER

2. COUNTERSUNK WASHER 7. BOLT
3. BOLT 8. SKID TUBE
4. FLAT WASHER 9. FORWARD CROSSTUBE
5. NUT
Figure 606. Forward Spacer Fitting Inspections
Page 607
D. Fluid Level Check of the Landing Gear (b). The reservoir is near empty when the
Damper Assemblies window shows red.
(Ref. Figure 607) (2). If the red has reached or is below the
(1). Make sure the fluid level indicator (1) is second notch (3), fill the reservoir (ref.
between the first notch (2) and second Section 12-00-00, Landing Gear).
notch (3) of the window.
NOTE: This lets the fluid contract.
(a). The reservoir is near full when the
window shows green.
NOTE: When the reservoir is full, the window
shows green with a very thin wedge of red at
the first notch (2). This is because the reser
voir is not completely full to let the fluid ex
pand.
2 3
RED 1
GREEN FULL EMPTY

9G32-010A
1. FLUID LEVEL INDICATOR 3. SECOND NOTCH
2. FIRST NOTCH
Figure 607. Damper Fluid Level Indicator
Page 608
E. Landing Gear Damper Assembly (4). Make sure there is a clearance between
Inspection damper cover and inner cover.
(Ref. Figure 608) (a). Replace damper (1) if there is binding

or interference.
(1). Examine dampers (1) for cracks, dents, (5). Examine mating surfaces of dampers
gouges, and corrosion. (1) and skid tubes (12) for damage,
deformation, and corrosion.
permitted. (a). No damage deformation, or corrosion
permitted.
(2). Examine dampers (1) for too much
leakage. (6). Examine mating surfaces of dampers
(1) and aft crosstube (13) for damage,
(a). Too much leakage not permitted. deformation, or corrosion.
(3). Examine dampers (1) for missing nuts (a). No damage deformation, or corrosion
(5, 11), bolts (3, 7, 9), and washers (2, 4, permitted.
6, 8, 10). (7). Examine 4 drain ports of damper (1) for
blockage.
(a). Replace missing nuts (5, 11), bolts (3,
7, 9), and washers (2, 4, 6, 8, 10). (a). No blockage permitted.
13 3
2
1
9
8
10
4 11
5
DRAIN PORTS (BOTH SIDES)
12 0.030 INCH (0.76 MM) APPROX

7
6
0.300 INCH (7.62 MM) APPROX 9G32-024B

1. DAMPER 8. COUNTERSUNK WASHER
2. COUNTERSUNK WASHER 9. BOLT
3. BOLT 10. FLAT WASHER
4. FLAT WASHER 11. NUT
5. NUT 12. SKID TUBE
6. FLAT WASHER 13. AFT CROSSTUBE
7. BOLT
Figure 608. Damper Inspection
Page 609
18.5 INCH 7
(46.99 CM)
10 INCH
(25.40 CM)
13 INCH
(33.02 CM)
11
OPTIONAL SKID TUBE STEP 12

10
3 2
2
11
12 10
10
11 9
11
1 10
9
13 INCH
(33.02 CM)
12
10
12 INCH
7 (30.48 CM) 10 15 13
8 9 14
6 14
15
5 6
7
9G32-018D
1. SKID TUBE 9. BOLT

2. PLUG 10. WASHER
3. STEP 11. SPACER
4. LARGE STEP 12. NUT
5. FORWARD ABRASION STRIP 13. AFT ABRASION STRIP
7. SCREW 15. SCREW
8. MIDDLE ABRASION STRIP
Figure 609. Skid Tube Inspections
Page 610
F. Skid Tube Assembly Inspection (9). Examine skid tube plugs (2) for cracks.
(Ref. Figure 609) (a). No cracks permitted.
(1). Jack helicopter (ref. Section 07-10-00). (10). Examine steps (3) or large steps (4) for
corrosion, cracks, loose rivets, and wear.
(2). Examine skid tubes (1) for cracks and
dents. (a). No corrosion, loose rivets, or wear
permitted.
(a). No cracks or dents permitted.
(11). Examine skid tube abrasion strips (5, 8,
(3). Examine skid tubes (1) for corrosion, 13) to skid tube (1) bolt holes for
nicks, and scratches in the nonrepair damage, deformation, and corrosion.
able area between sections B and C.
(a). No corrosion, nicks, or scratches permitted.
permitted.
(12). Examine abrasion strips (5, 8, 13) for
(4). Examine Section A for corrosion, corrosion, cracks, looseness, and wear.
nicks, and scratches. (a). No corrosion, cracks, looseness, or
(a). Damage deeper than 0.010 inch wear permitted.
(0.25 mm) not permitted. (13). Examine abrasion strips (5, 8, 13) for
(5). Examine Section B for corrosion, missing nuts (12), spacers (11), washers
nicks, and scratches. (6, 10), screws (7, 15), and bolts (9).
(a). Replace missing nuts (12), spacers
(a). Damage deeper than 0.010 inch
(11), washers (6, 10), screws (7, 15),
(0.25 mm) not permitted.
and bolts (9).
(6). Examine Section C for corrosion, (14). Examine skid tube ground handling for
nicks, and scratches. missing nuts (12), spacers (11), washers
(a). Damage deeper than 0.025 inch (10), and bolts (9).
(0.64 mm) not permitted. (a). Replace missing nuts (12), spacers
(7). Examine Section D for corrosion, (11), washers (10), and bolts (9).
nicks, and scratches. (15). Examine nuts (12), spacers (11),
washers (10), and bolts (9) for corrosion.
(a). Damage deeper than 0.040 inch
(1.02 mm) not permitted. (a). No corrosion permitted.
(8). Examine skid tubes (1) for missing skid (16). Examine skid tube ground handling
tube plugs (2). bolt holes for corrosion.
(a). Replace missing skid tube plugs (2). (a). No corrosion permitted.
Page 611
Page 612
LANDING GEAR
REPAIRS
1. Landing Gear Damper Assemblies compound (C211) from drain ports with
A. Drain Port Repair a brush, scribe, or other instrument.
(Ref. Figure 801) (2). Make sure drain ports are open after
Do not damage adjacent repair.
CAUTION material when you remove
unwanted material or sealing compound
(C211).
(1). Remove unwanted material or sealing
DRAIN PORTS (BOTH SIDES)
0.030 INCH (0.76 MM) APPROX
0.300 INCH (7.62 MM) APPROX
9G32026
Figure 801. Location of Damper Drain Ports
Page 801
18.5 INCH
(46.99 CM)
10 INCH
(25.40 CM)
13 INCH
(33.02 CM)

OPTIONAL SKID TUBE STEP
DAMPER BOLT HOLE

(8 PL)
12 INCH
(30.48 CM)
LEFT SIDE SHOWN

13 INCH RIGHT SIDE TYPICAL
(33.02 CM)
9G32-025B
Figure 802. Skid Tube Repairable Sections
2. LeftHand and RightHand Skid Tube (1). Blend out nicks, scratches, or corrosion
Assemblies in repairable sections A, B, C, and D
A. Blend Repair (ref. CSP-SPM, Section 20-40-00,
Mechanical Defects).
(Ref. Figure 802)
(2). Refinish the blended area (ref. CSP-
CAUTION SPM, Section 20-30-00).
Do not remove material and do the blend NOTE: Material removal and repair procedure
repair more than once on a surface. can be done one time only on a surface.
Material removed from the surface of
Section A cannot be deeper than 0.010 3. Nonslip Surfaces
inch (0.25 mm).
(Ref. CSP-SPM, Section 20-30-00, Landing
Material removed from the surface of Gear Nonslip Surface)
Section B cannot be deeper than 0.010
inch (0.25 mm).
Section C cannot be deeper than 0.025
inch (0.64 mm).
Section D cannot be deeper than 0.040
inch (1.02 mm).
Do not remove material adjacent to the
bolt holes for the landing gear damper as
sembly in Section D.
Page 802
Section
324000
Ground Handling
Wheels
GROUND HANDLING WHEELS

1. Ground Handling Wheel Set C. Steel Rims
The requirement to ground transport the MD The steel rims rotate on a spindle by means of
Explorer on prepared surfaces is met be means an inner and outer tapered roller bearing with
of skid mounted ground handling wheels. an external grease fitting on the hub for
periodic servicing.
A. Description and Function
(1). Inspect wheels for cracks and defects,
(Ref. Figure 201) none allowed.
(2). At regular intervals (yearly) repack
Special Tools wheel bearings.
(Ref. CSPSPM) D. Main Frame Body
Item Nomenclature
T101 Ground Handling Wheel Set The main body is a rectangular box frame
weldment constructed from 1/4 1020 steel
plate.
The ground handling wheel set (T101) consists
E. Hydraulic Jack
of two each dual wheel assemblies, which
support a fully equipped MD Explorer approxi A six ton jack is held in place on the main
mately three inches above the ground. frame by a support plate.
The Wheel Assembly consists of two pneumat The jack retains a vertical position, during
ic tires, rims, spindles, a main frame body, raising and lowering of the wheels.
hydraulic jack, and attach cradle.
The ram of the hydraulic jack is in constant
B. Tires contact with the upper cross frame of the main
body, providing vertical pumping leverage
The Wheel Assembly has two 14 inch diame forcing the spindle and wheels down.
ter, 500 x 5 Cleveland with 10 ply, 65 psi
(1). At regular intervals (yearly) inspect
Goodyear tires mounted on steel rims, with a
hydraulic jacks for proper fluid levels.
load rating of at least 1120 lb at 35 mph.
F. Attach Cradle
(1). At regular intervals examine tire
pressure and inflate to 65 psi. Permanently fixed to the bottom of the main
body is a slotted lock down cradle. The cradle
(2). Inspect tires for wear and cuts, none is constructed from 3/16 steel plate and is
allowed. contoured to conform to the MD Explorer skid.
Page 201
32-40-00 Original
VIEW ROTATED
9G32017A
1. GROUND HANDLING WHEEL SET (T101)
Figure 201. Ground Handling Wheel Set
Page 202
Original 32-40-00
Chapter
DOORS AND WINDOWS

TABLE OF CONTENTS
52-00-00 Doors and Windows . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A

1. Doors and Windows - General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Crew/Cockpit Door Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
3. Cabin/Passenger Door Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
4. Baggage/Cargo Door Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Figure 1.Cockpit Door Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Figure 2.Crew Door Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Figure 3.Cabin Door Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Figure 4.Cabin Door Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Figure 5.Baggage Door Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Fault Isolation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
1. Doors Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Table 101.Doors Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
1. Cockpit Door Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
A. Cockpit Door Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
B. Cockpit Door Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
2. Cockpit Door Assembly Quick Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
A. Cockpit Door Assembly Quick Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
B. Cockpit Door Assembly Quick Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 402
3. Cockpit Door Assembly (With Outside Quick Release Pins) . . . . . . . . . . . . . . . . . . . . 402
A. Cockpit Door Assembly Removal (With Outside Quick Release Pins) . . . . . . . . . 402
B. Cockpit Door Assembly Installation (With Outside Quick Release Pins) . . . . . . . 402
4. Gas Strut - Cockpit Door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 403
A. Gas Strut Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 403
B. Gas Strut Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 403
5. Hinge - Flanged Housing - Cockpit Door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 403
A. Flanged Housing Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 403
B. Flanged Housing Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 404
6. Fork Assembly, Cockpit Door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 404
A. Fork Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 404
B. Fork Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 404
7. Pull Rod Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 404
A. Pull Rod Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 404
B. Pull Rod Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 405
Page i

8. Stop Bracket, Cockpit Door Release . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 405
A. Stop Bracket Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 405
B. Stop Bracket Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 405
9. Retaining Boss, Cockpit Door Release . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 405
A. Retaining Boss Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 405
B. Retaining Boss Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 405
10. Shaft, Cockpit Door Release . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 406
A. Shaft Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 406
B. Shaft Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 406
11. Flanged Fitting, Cockpit Door Release . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 406
A. Flanged Fitting Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 406
B. Flanged Fitting Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 406
12. Handle, Cockpit Door Release . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 407
A. Handle Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 407
B. Handle Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 407
13. Door Latch Mechanism, Cockpit (Original Configuration) . . . . . . . . . . . . . . . . . . . . . 407
A. Door Latch Mechanism Removal (Original Configuration) . . . . . . . . . . . . . . . . . . . 407
B. Door Latch Mechanism Installation (Original Configuration) . . . . . . . . . . . . . . . . 408
14. Door Latch Mechanism, Cockpit (New Configuration) . . . . . . . . . . . . . . . . . . . . . . . . . 409
A. Door Latch Mechanism Removal (New Configuration) . . . . . . . . . . . . . . . . . . . . . . 409
B. Door Latch Mechanism Installation (New Configuration . . . . . . . . . . . . . . . . . . . . 409
15. Cockpit Door Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 410
A. Window Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 410
B. Window Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 410
16. Window Seal, Cockpit Door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 411
A. Seal Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 411
B. Seal Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 411
Figure 401.Cockpit Door/Window Assembly (Sheet 1 of 4) . . . . . . . . . . . . . . . . . . . 412
17. Cabin Door Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 416
A. Cabin Door Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 416
B. Cabin Door Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 416
18. Door Upper Fitting Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 416
A. Door Upper Fitting Components Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 416
B. Door Upper Fitting Components Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 417
19. Lower Aft Cabin Door Link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 417
A. Lower Aft Cabin Door Link Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 417
Page ii

B. Lower Aft Cabin Door Link Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 417
20. Lower Aft Carriage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 417
A. Lower Aft Carriage Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 417
B. Lower Aft Carriage Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 417
21. Vertical Lower Aft Carriage Track Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 418
A. Vertical Track Roller Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 418
B. Vertical Track Roller Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 418
22. Horizontal Lower Aft Carriage Track Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 418
A. Horizontal Track Roller Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 418
B. Horizontal Track Roller Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 418
23. Cabin Door Fairing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 418
A. Cabin Door Fairing Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 418
B. Cabin Door Fairing Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 418
24. Cabin Door, Door Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 418
A. Door Stop Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 418
B. Door Stop Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 419
25. Cabin Door Stop Pad . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 419
A. Stop Pad Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 419
B. Stop Pad Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 419
26. Lower Forward Cabin Door Pivot Lug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 419
A. Pivot Lug Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 419
B. Pivot Lug Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 419
27. Pivot Lug Vertical Track Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 419
A. Pivot Lug Vertical Track Roller Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 419
B. Pivot Lug Track Vertical Roller Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 419
28. Pivot Lug Horizontal Track Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 420
A. Pivot Lug Horizontal Track Roller Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 420
B. Pivot Lug Horizontal Track Roller Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 420
29. Cabin Door Latch Mechanism (EARLY CONFIG) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 420
A. Door Latch Mechanism Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 420
B. Door Latch Mechanism Installation and Rigging . . . . . . . . . . . . . . . . . . . . . . . . . . . 420
30. Cabin Door Bolting System (CURRENT CONFIG) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 421
A. Bolting System Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 421
B. Bolting System Installation and Rigging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 422
31. Cabin Door Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 423
A. Window Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 423
Page iii

B. Window Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 423
32. Cabin Door Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 424
A. Cabin Door Fitting Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 424
B. Cabin Door Fitting Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 424
Figure 402.Cabin Door/Window With EARLY CONFIG Latch Mechanism
(Sheet 1 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 425
Figure 403.Cabin Door Bolting System (CURRENT CONFIG) . . . . . . . . . . . . . . 428
33. Baggage Door Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 429
A. Baggage Door Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 429
B. Baggage Door Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 429
34. Door Strut Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 429
A. Door Strut Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 429
B. Door Strut Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 429
35. Strut Bracket Hinge Half . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 429
A. Strut Bracket Hinge Half Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 429
B. Strut Bracket Hinge Half Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 429
36. Strut Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 430
A. Strut Bracket Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 430
B. Strut Bracket Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 430
37. Door Latch Mechanism, Baggage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 430
A. Door Latch Mechanism Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 430
B. Door Latch Mechanism Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 430
38. Lower Hinges, Door and Spoiler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 431
A. Lower Hinge Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 431
B. Lower Hinge Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 432
39. Upper Hinge, Door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 432
A. Upper Door Hinge Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 432
B. Upper Door Hinge Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 432
40. Upper Hinge, Fuselage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 432
A. Upper Fuselage Hinge Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 432
B. Upper Fuselage Hinge Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 432
41. Hinge Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 432
A. Hinge Stop Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 432
B. Hinge Stop Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 432
Figure 404.Baggage Door Assembly (Sheet 1 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . 433
42. Door Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 435
A. Door Seal Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 435
Page iv

B. Door Seal Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 435
43. Baggage Door Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 436
A. Baggage Door Switch (EARLY CONFIG) Removal . . . . . . . . . . . . . . . . . . . . . . . . . . 436
B. Baggage Door Switch (EARLY CONFIG) Installation . . . . . . . . . . . . . . . . . . . . . . . 436
C. Baggage Door Switch Bracket (EARLY CONFIG) Removal . . . . . . . . . . . . . . . . . . 436
D. Baggage Door Switch Bracket (EARLY CONFIG) Installation . . . . . . . . . . . . . . . 436
E. Baggage Door Switch (CURRENT CONFIG) Removal . . . . . . . . . . . . . . . . . . . . . . 436
F. Baggage Door Switch (CURRENT CONFIG) Installation . . . . . . . . . . . . . . . . . . . 436
G. Baggage Door Switch Bracket (CURRENT CONFIG) Removal . . . . . . . . . . . . . . 436
H. Baggage Door Switch Bracket (CURRENT CONFIG) Installation . . . . . . . . . . . . 436
Figure 405.Baggage Door Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 437
Inspection/Test/Rigging Verification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601
1. Doors/Windows . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601
A. Doors/Windows Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601
Figure 601.Window Damage Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 602
2. Doors Operational Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 602
A. Cockpit Doors Operational Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 602
B. Cabin Doors Operational Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 602
C. Baggage Door Operational Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 603
3. Door Latch Mechanism Rigging Verification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 603
A. Cockpit Door Latch Mechanism Rigging Verification - Original Configuration 603
B. Cockpit Door Latch Mechanism Rigging Verification - New Configuration . . . . 604
C. Cabin Door Latch Mechanism Rigging Verification . . . . . . . . . . . . . . . . . . . . . . . . . 604
D. Baggage Door Latch Mechanism Rigging Verification . . . . . . . . . . . . . . . . . . . . . . . 604
Figure 602.Cockpit Door Latch Mechanism Rigging Verification . . . . . . . . . . . . . 605
Figure 603.Cabin and Baggage Door Latch Mechanism Rigging Verification
(Sheet 1 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 606
4. Baggage Door Switch Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 608
A. Baggage Door Switch Adjustment (EARLY CONFIG) . . . . . . . . . . . . . . . . . . . . . . . 608
B. Baggage Door Switch Adjustment (CURRENT CONFIG) . . . . . . . . . . . . . . . . . . . 608
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 801
1. Doors / Windows . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 801
A. Cabin Door Window Water Leak Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 801
Page v

Page vi
Section
520000
Doors and Windows
DOORS AND WINDOWS

1. Doors and Windows General 3. Cabin/Passenger Door Assemblies
One crew door and window assembly is (Ref. Figure 3 and Figure 4)
mounted in a door frame structure or door
pillar assembly on each side of the aircraft. The cabin doors consist of a graphite/epoxy
One cabin door and window assembly is inner and outer skin adhesively bonded
mounted on a sliding track mechanism on each together to form a box section assembly. The
side of the aircraft. One baggage door assem cabin doors operate on rollers and an upper
bly is mounted in the rear door frame struc and lower door track mechanism which allows
ture. These attachment substructures are part the doors to be slid aft for access to the cabin
of the fuselage structure. area. Each door has one window transparency
mounted to the door structure by means of a
2. Crew/Cockpit Door Assemblies Z shaped window seal that mounts to the
periphery of the window and the mating flange
(Ref. Figure 1 and Figure 2) of the door frame. An emergency pull strap is
The crew or cockpit door assemblies consist of incorporated in the window mounting which
a graphite/epoxy inner and outer skin adhe allows the window to be pulled in for emergen
sively bonded together to form a box section cy egress. The cabin doors have a locking
assembly. The cockpit doors operate on a latching door mechanism that can be opened
pivoting hinge mechanism. Each door has one from the inside or outside.
window transparency mounted to the door
4. Baggage/Cargo Door Assembly
structure by means of a Z shaped window
seal that mounts to the periphery of the (Ref. Figure 5)
window and the mating flange of the door
frame. The door assemblies are secured with a The baggage/cargo door is a graphite/epoxy
locking latching door mechanism that can be faced Nomex honeycomb cored structure.
opened from the inside or outside. A quick Facings are typically two outer plies and one
release mechanism is also standard on each inner ply with doubler plies adjacent to hinge
door assembly. Currently, there is an optional points. The baggage door operates on a
door with quick release pins on the outside. pivoting hinge mechanism opened from the
This option door does not come with gas struts outside for access to the rear baggage/cargo
(Ref. CSP-900RMM-2, Section 01-00-00, area. The baggage/cargo door has a locking
Optional Equipment List). latching mechanism.
Page 1
COCKPIT
SIDE DOOR
COCKPIT DOOR
RELEASE MECHANISM
C
DOOR HINGE
B
VIEW LOOKING OUTBOARD

LEFT SIDE C
A-A
B
GAS STRUT
B-B
COCKPIT DOOR
C-C RELEASE MECHANISM
9G52003
Figure 1. Cockpit Door Assembly
Page 2
Original 52-00-00
COCKPIT SIDE
(DOOR) WINDOW
9G52002
Figure 2. Crew Door Window
Page 3
52-00-00 Original
DOOR UPPER
TRACK
& FITTING
B-B E
C
LINK ASSY
LOWER , AFT
CABIN SIDE DOOR CABIN DOOR
CABIN DOOR
CARRIAGE
C
E
TRACK ROLLER
D D
C-C
PIVOT-LUG ASSY
LOWER, FWD
CABIN DOOR
TRACK ROLLER
D-D
DOOR TRACK
E-E CARRIAGE ROLLER
9G52004A
Figure 3. Cabin Door Assembly
Page 4
Original 52-00-00
CABIN SIDE
WINDOW
9G52001
Figure 4. Cabin Door Window
Page 5
52-00-00 Original
9G52006
Figure 5. Baggage Door Assembly
Page 6
Original 52-00-00
DOORS AND WINDOWS

FAULT ISOLATION
1. Doors Troubleshooting
brief summary of doors faults, which may be
encountered (Ref. Table 101).
Table 101. Doors Troubleshooting
Latching mechanism does Latching mechanism out of Verify latch mechanism rigging 520000
not disengage. adjustment. and adjust as necessary.
Latching mechanism worn, Inspect mechanism, replace if
or broken. necessary.
Door does not open Broken or obstructed hinge Identify problem area, remove 520000
completely. mechanism. and replace.
Latching mechanism does Verify latch mechanism rigging
not fully open or disengage. and adjust as necessary.
Doors do not close Door seal may be deformed Replace door seal. 520000
completely. and restricting door from
closing properly.
Door handle is not lined up Reactivate door handle
with slam position on door mechanism to the open
decal. position, release and try to
close again.
Some other obstruction may Open door, remove
be inhibiting hinge or door obstructions and close again.
track.
Latching mechanism does Deformation or misalignment Realign striker plate, adjust or 520000
not fully engage with door with striker plate receptacle. replace.
closed.
Handle mechanism is not Verify latch mechanism rigging
fully rotating or push/pull rod and adjust as necessary.
does not engage receptacle.
Push/pull rod may be Inspect rod, lubricate or replace
binding or bent. if necessary.
Latch block may be sticking Lubricate latch block or replace
or binding. if necessary.
Page 101
Page 102
DOORS AND WINDOWS

1. Cockpit Door Assembly Grease, Aircraft (C107)
A. Cockpit Door Assembly Removal
(Ref. Figure 401)
NOTE: Left and right side door assemblies are (2). Apply aircraft grease (C107) to bush
typical. ings (7) and bolts (6).
(3). Install bushings (7), bolts (6), washers
(1). Disengage door latching mechanism (1) (5) and nuts (4) securing door assembly
to open cockpit door assembly (2). (2) to fork assembly (13).
(2). With cockpit door (2) swung in open (4). Tighten nuts and install new cotter
position, pull lower end of gas strut (9) pins.
up away from pivot post ball fitting (33)
to remove. (5). Activate door release handle (16) to
permit attachment of door restraint end
When activating cockpit door re fitting (31) and strap to lower fork
CAUTION lease mechanism, spacer (29) or assembly (13).
washer (30) may fall loose as retaining
bosses (12) are removed. (6). Safety door release handle (16) to
airframe using lockwire (C715).
(3). Activate cockpit door release handle (7). Apply aircraft grease (C107) to ball
(16) to release door restraint end fitting fitting (33).
(31) and strap.
(8). Push down end of gas strut (9) onto
(4). Re-engage release handle (16) to secure pivot post ball fitting (33) to attach.
door fork assemblies (13).
(9). Close door (2) and re-engage door
(5). Remove and discard cotter pins (3). latching mechanism (1).
Remove nuts (4), washers (5), bolts (6)
and bushings (7) that attach hinge 2. Cockpit Door Assembly Quick Removal
mechanism (8) of cockpit door assembly A. Cockpit Door Assembly Quick Removal
(2) to door fork assembly (13).
(Ref. Figure 401)
(6). Remove door (2).
(1). Disengage door latching mechanism (1)
B. Cockpit Door Assembly Installation to open cockpit door assembly (2).
(Ref. Figure 401) (2). With cockpit door (2) swung in open
position, pull lower end of gas strut (9)
Consumable Materials to remove.
(Ref. CSPSPM)
Item Nomenclature When activating cockpit door re
CAUTION lease mechanism, spacer (29) or
C107 Grease, Aircraft washer (30) may fall loose as retaining
C715 Lockwire bosses (12) are removed.
(3). Activate cockpit door release handle
(1). Align hinge mechanism (8) of cockpit (16) to disengage pull rod assemblies
door assembly (2) with door fork (11) and release cockpit door retaining
assembly (13). boss (12).
Page 401
(4). Remove complete door assembly (2) A. Cockpit Door Assembly Removal (With
with retainers (27) and fork assemblies Outside Quick Release Pins)
(13) attached.
(Ref. Figure 401)
B. Cockpit Door Assembly Quick
Outside - Removal from outside the helicop
Installation
ter.
(Ref. Figure 401) (1). Open cockpit door assembly.
(2). Disengage and remove snap pin (82)
from removable restraint assembly
(Ref. CSPSPM)
(83).
Item Nomenclature
C107 Grease, Aircraft (3). Move door restraint aside.
C715 Lockwire (4). Replace door snap pin into removable
restraint assembly.
(1). Install cockpit door assembly (2) with (5). Remove lower and upper door quick
retainers (27) and fork assemblies (13) release pins (84) while supporting door
attached. with hand.
(2). Attach door restraint end fitting (31) (6). Pull door away from aircraft.
and strap to lower fork assembly (13).
Inside - Removal from inside the helicopter.
(7). Open cockpit door assembly.
When activating cockpit door re
CAUTION lease mechanism, spacer (29) or
washer (30) may fall loose as retaining
(3). Apply aircraft grease (C107) to end of bosses (12) are removed.
pull rod assemblies (11).
(4). Align pull rods (11) with retaining boss (16) to disengage pull rod assemblies
(12). (11) and release cockpit door retaining
boss (12).
(5). Engage cockpit door release handle (16)
and verify insertion of pull rods (11) (9). Remove complete door assembly (2)
into retaining boss (12). with retainers (27) and fork assemblies
(13) attached.
(6). Safety door release handle (16) to
B. Cockpit Door Assembly Installation (With
Outside Quick Release Pins)
(7). Ensure that lower pivot post ball fitting (Ref. Figure 401)
(33) is lubricated with aircraft grease
(C107) prior to installation of gas strut
(9). Consumable Materials
(Ref. CSPSPM)
(8). Push down lower end of gas strut (9) Item Nomenclature
onto lower pivot post ball fitting (33) to C107 Grease, Aircraft
attach.
C715 Lockwire
3. Cockpit Door Assembly (With Outside
Quick Release Pins) Outside - Installation from outside the
helicopter.
NOTE: Helicopters equipped with outside
quick release pins do not have a gas strut (1). Align door hinges with airframe hinge
installed. halves.
Page 402
(2). Insert lower and upper door quick B. Gas Strut Installation
release pins (84).
(Ref. Figure 401)
(3). Remove snap pin (82) from removable
restraint assembly (83). Consumable Materials
(Ref. CSPSPM)
(4). Align restraint assembly halves and
Item Nomenclature
insert snap pin.
C107 Grease, Aircraft
(5). Close cockpit door assembly.
Inside - Installation from inside the Grease, Aircraft (C107)
helicopter.
(6). Install cockpit door assembly (2) with
retainers (27) and fork assemblies (13)
attached. (1). Ensure that pivot post ball fittings (33)
(7). Attach door removable restraint (83) are lubricated with aircraft grease
and strap to lower fork assembly (13). (C107) prior to installation of gas strut
(9).
(2). Push down upper end of gas strut (9)
onto pivot post ball fitting (33) to
attach.
(3). Push down lower end of gas strut (9)
(8). Apply aircraft grease (C107) to end of onto lower pivot post ball fitting (33) to
pull rod assemblies (11). attach.
(9). Align pull rods (11) with retaining boss (4). Install retaining spring clip (34)
(12). securing upper end of gas strut (9) to
pivot post ball fitting (33).
(10). Engage cockpit door release handle (16)
and verify insertion of pull rods (11) 5. Hinge Flanged Housing Cockpit Door
into retaining boss (12). A. Flanged Housing Removal
(11). Safety door release handle (16) to (Ref. Figure 401)
NOTE: Left and Right side are typical.
4. Gas Strut Cockpit Door (1). Remove cockpit door assembly (2) (Ref.
A. Gas Strut Removal Section 52-00-00).
(Ref. Figure 401)
(16) to disengage pull rod assembly
NOTE: Left and Right side are typical. (11).
(1). Remove retaining spring clip (34) that (3). Remove door fork assemblies (13).
secures upper end of gas strut (9) to Caution should be taken when
pivot post ball fitting (33). CAUTION removing sealing compound
from around housings and other bonded
(2). With cockpit door (2) swung in open
components so as not to damage surround
position, pull lower end of gas strut (9)
ing fuselage surfaces.
to remove. (4). Remove bond from upper retaining boss
(12) and spacers (28 and 29).
(3). Pull upper end of gas strut (9) up away
from pivot post ball fitting (33) to (5). Remove rivets (14) that attach flanged
remove. housings (15) to airframe.
Page 403
(6). Remove sealant from around housing (7). Activate cockpit door release handle
(15) and remove housing. (16) and verify insertion of pull rods
(11) into retaining boss (12).
B. Flanged Housing Installation
(8). Install cockpit door assembly (2) (Ref.
6. Fork Assembly, Cockpit Door
Consumable Materials A. Fork Assembly Removal
(Ref. CSPSPM)
C107 Grease, Aircraft NOTE: Left and Right side are typical.
C206 Sealing Compound (1). Remove cockpit door assembly (2) (Ref.
C310 Primer Section 52-00-00).
Primer (C310) (16) to disengage pull rod assemblies
(11).
(3). Remove fork assemblies (13) and
retainers (27).
B. Fork Assembly Installation
(1). Wet install rivets (14) into flanged
housing (15) with primer (C310). (Ref. Figure 401)
Sealing Compound (C206) Consumable Materials

(Ref. CSPSPM)
Item Nomenclature
(2). Fillet seal edges of flanged housing (15)

(1). Install cockpit door fork assemblies (13)
using sealing compound (C206).
with retainers (27).
(3). Bond spacers (28 and 29) to upper (2). Install door restraint end fitting (31) on
flanged housing (15) with sealing lower fork assembly (13).
compound (C206).
NOTE: Ensure retaining boss (12) is bonded in
correct orientation for pull rod (11) installa
tion.
(4). Bond upper retaining boss (12) to (3). Apply aircraft grease (C107) to ends of
spacer (29) with sealing compound pull rod assemblies (11).
(C206).
(5). Install cockpit door fork assemblies (13) (16) and verify insertion of pull rods
(Ref. Section 52-00-00). (11) into retaining boss (12).
(5). Install cockpit door assembly (2) (Ref.
Grease, Aircraft (C107) Section 52-00-00).
7. Pull Rod Assembly
A. Pull Rod Assembly Removal
(Ref. Figure 401)
(6). Apply aircraft grease (C107) to ends of
pull rod assemblies. NOTE: Left and Right side are typical.
Page 404
(1). Activate cockpit door release handle B. Stop Bracket Installation

(16) to disengage pull rod assemblies
(11) from retaining boss (12). (Ref. Figure 401)
(2). Rotate pull rods (11) up and around to Consumable Materials

remove from door release handle (16). (Ref. CSPSPM)
Item Nomenclature
B. Pull Rod Assembly Installation C310 Primer
(Ref. Figure 401) Primer (C310)
(Ref. CSPSPM)
Item Nomenclature
(1). Wet install rivets (21) with primer
(C310) attaching cockpit door release
stop bracket (19) to fuselage door
frame.
(1). Insert end of pull rod (11) into door
release handle (16). (2). Install washer (18) and nut (17)
securing stop bracket (19) to cockpit
Grease, Aircraft (C107) door release shaft (20).
9. Retaining Boss, Cockpit Door Release

A. Retaining Boss Removal
(Ref. Figure 401)
(2). Apply aircraft grease (C107) to end of
pull rod that inserts into retaining boss NOTE: Left and Right side are typical.
(12). (1). Disengage pull rod assemblies (11) from
cockpit door assembly retaining boss
(3). Insert this end of pull rod (11) into (12).
retaining boss (12) while moving door
release handle (16) back to engaged Caution should be taken when
position.
CAUTION removing sealing compound
from around bonded components so as not to
damage surrounding fuselage surfaces.
8. Stop Bracket, Cockpit Door Release
(2). Remove bond from retaining boss (12)
A. Stop Bracket Removal surfaces.
(3). Remove retaining boss (12).
(Ref. Figure 401)
B. Retaining Boss Installation
NOTE: Left and Right side are typical. (Ref. Figure 401)
(1). Remove nut (17) and washer (18) that
attach cockpit door release stop bracket Consumable Materials
(19) to cockpit door release shaft (20). (Ref. CSPSPM)
Item Nomenclature
(2). Remove rivets (21) that attach stop C107 Grease, Aircraft
bracket (19) to fuselage door frame and C206 Sealing Compound
remove bracket (19).
Page 405
Sealing Compound (C206) (1). Insert cockpit door release shaft (20)
into cockpit door release flanged fitting
(23) and secure with tubular spring pin
(22).
(2). Install cockpit door release handle (16).
(1). Bond upper retaining boss (12) to
spacer (29) using sealing compound Primer (C310)
(C206).
(2). Bond lower retaining boss (12) to door
restraint end fitting (31) using sealing
compound (C206).
Grease, Aircraft (C107) (C310) attaching cockpit door release
frame.
(4). Install washer (18) and nut (17)
attaching stop bracket (19) and door
(3). Apply aircraft aircraft grease (C107) to release handle (16) to shaft (20).
ends of pull rod assemblies (11).
(5). Safety door release handle (16) to
(4). Activate cockpit door release handle airframe using lockwire (C715).
(16) and verify insertion of pull rods
(11) into retaining boss (12). 11. Flanged Fitting, Cockpit Door Release
A. Flanged Fitting Removal
10. Shaft, Cockpit Door Release
(Ref. Figure 401)
A. Shaft Removal
(Ref. Figure 401)
Caution should be taken when
NOTE: Left and Right side are typical. CAUTION removing sealing compound
from around bonded components so as not to
(1). Remove nut (17) and washer (18) that
damage surrounding fuselage surfaces.
attach cockpit door release stop bracket
(19) to cockpit door release shaft (20) . (1). Remove cockpit door release stop
bracket (19) and cockpit door release
(2). Remove rivets (21) that attach stop handle (16) Ref. Section 52-00-00).
bracket (19) to fuselage door frame.
(2). Remove rivets (24) that attach cockpit
(3). Remove cockpit door release handle (16) door release flanged fitting (23) to
(4). Remove tubular spring pin (22) from fuselage door frame.
cockpit door release flanged fitting (23) (3). Remove sealant from around flanged
and remove shaft (20). fitting (23) and remove fitting.
B. Shaft Installation B. Flanged Fitting Installation
Consumable Materials Consumable Materials

(Ref. CSPSPM) (Ref. CSPSPM)
Item Nomenclature Item Nomenclature
C310 Primer C310 Primer
C715 Lockwire C206 Sealing Compound
Page 406
Primer (C310) Grease, Aircraft (C107)
(1). Wet install rivets (24) with primer (1). Install cockpit door release handle (16)
(C310) attaching cockpit door release using aircraft grease (C107).
flanged fitting (23) to fuselage door Primer (C310)
frame.

(C310) attaching cockpit door release
(2). Fillet seal around edges of flanged frame.
fitting (23) using sealing compound
(C206). (3). Install washer (18) and nut (17)
attaching stop bracket (19) and handle
(3). Install cockpit door release handle (16) (16) to cockpit door release shaft (20).
and cockpit door release stop bracket
(19) Ref. Section 52-00-00). (4). Safety door release handle (16) to
12. Handle, Cockpit Door Release
13. Door Latch Mechanism, Cockpit (Original
A. Handle Removal Configuration)
(Ref. Figure 401) A. Door Latch Mechanism Removal

(Original Configuration)
(Ref. Figure 401)
(1). Disengage pull rod assembly (11) by NOTE: Left and Right side latch mechanisms
activating door release handle (16). are typical.
(2). Remove nut (17) and washer (18) that (1). Remove cockpit door assembly (2) (Ref.
attach cockpit door release stop bracket Section 52-00-00).
(19) to cockpit door release shaft (20).
(2). Remove (interior) cockpit door panel (Ref.
(3). Remove rivets (21) that attach stop Section 25-10-00).
bracket (19) to fuselage door frame and
remove bracket (19). (3). Remove return spring (63), spacer (62)
and clevis pin (61) from lower support
(4). Remove cockpit door release handle (16). plate assembly (41) and clevis (56).
B. Handle Installation (4). Remove and discard cotter pin (55).
Remove clevis pin (53) and washer (54)
(Ref. Figure 401) that attaches clevis (58) to lower latch
block (40).
Consumable Materials (5). Remove and discard cotter pin (55).
(Ref. CSPSPM) Remove clevis pin (53) and washer (54)
Item Nomenclature that attaches clevis (59) to link (52).
C310 Primer Remove clevis pin (53) and washer (54)
C715 Lockwire that attaches clevis (58) to upper latch
block (40).
Page 407
(7). Rotate clevis (56) down away from cable (6). Tighten hex fittings (48) at each
(49) without twisting cable (49). position.
(8). Remove and discard cotter pin (55). (7). Install screws (39) and washers (38)
Remove clevis pin (53) and washer (54) attaching support plate assemblies (41)
that attaches clevis assembly (56) to link and cable assembly (49) to door frame.
(52). (8). Install clevis pin (50) and cotter pin (51)
(9). Remove and discard cotter pin (51). attaching link (52) to housing assembly
Remove clevis pin (50) attaching link (42) bellcrank. Ensure that notch in
(52) to housing assembly (42) bellcrank. link faces in towards housing assembly.
(9). Install clevis pin (53), washer (54) and
(10). Remove screws (39) and washers (38) cotter pin (55) attaching clevis assem
that attach support plate assemblies (41) bly (56) to link (52).
and cable assembly (49) to door frame.
(10). Rotate clevis (56) up into cable (49) as
(11). Remove screws (37) and washers (38) far as it will go without twisting cable
that attach both upper and lower latch (49).
block assemblies (40).
(11). Rotate handle (47) to the fully closed
(12). Remove screws (44 and 45) that attach (SAFELOCK, horizontal) position.
interior door handle assembly (47). Ensure that hex nut (57) does not
bottom out against the support plate
(13). Remove screws (35 and 36) that attach (41).
exterior door handle (46), housing
assembly (42) and spacers (43) in door (12). Loosen hex nut (57) and adjust clevis
frame. (58) so that bolt in upper latch block
assembly (40) protrudes fully (full
B. Door Latch Mechanism Installation LOCK position).
(Original Configuration)
NOTE:
(Ref. Figure 401) This can be verified by pushing the bolt in
and confirming that there is no more than
0.010 in. (0.254 mm) of play.
(Ref. CSPSPM) Do not pull assembly down or rotate han
Item Nomenclature dle to accomplish the alignment. Align
ment should only be accomplished with
C239 Sealant
everything in full LOCK position.
(1). Install screws (35 and 36) attaching cotter pin (55) attaching clevis (58) to
exterior door handle (46), housing upper latch block (40).
assembly (42) and spacers (43) in door
frame. Sealant (C239)
(2). Install screws (44 and 45) attaching

interior door handle assembly (47).
(3). Install screws (37) and washers (38) (14). Apply sealant (C239) and tighten hex
attaching both upper and lower latch nut (57).
block assemblies (40).
(15). Attach clevis (59) to one end of turn
(4). Loosen hex fittings (48) on each end of buckle rod (60) and clevis (58) with hex
cable assembly (49). nut (57) to other end of rod.
(5). Adjust support plate assemblies (41) so (16). Install clevis pin (53), washer (54) and
that, when installed, they will line up cotter pin (55) attaching clevis (59) to
with holes in doors. link (52).
Page 408
(17). Install clevis pin (53), washer (54) and sion spring (71) and connecting tube
cotter pin (55) attaching clevis (58) to (76).
lower latch block assembly (40).
(18). Loosen hex nut (57) and adjust turn Remove clevis pin (68) and washer (69)
buckle rod (60) so that bolt in lower that attaches clevis (75) to upper latch
latch block assembly (40) protrudes block assembly (40).
fully (full LOCK position).
(5). Remove screw (72), washer (73) and
NOTE: This can be verified by pushing the bolt spacer (74) that attaches extension
in and confirming that there is no more than spring (71) to door.
0.010 in. (0.254 mm) of play. (6). Remove and discard cotter pin (70).
Sealant (C239) Remove clevis pin (68) and washer (69)
that attaches clevis (58) to lower latch
block assembly (40).
(7). Remove turnbuckle rod (60) from clevis
(67).
(19). Apply sealant (C239) and tighten hex
nut (57). (8). Remove and discard cotter pin (66).
Remove clevis pin (64) and washer (65)
(20). Install clevis pin (61), spacer (62) and that attaches clevis (67) to housing
return spring (63) through clevis (56) assembly (42) bellcrank.
and attach to lower support plate
assembly (41).
that attach both upper and lower latch
(21). Install (interior) cockpit door panel block assemblies (40) to door.
(Ref. Section 25-10-00). (10). Remove screws (44 and 45) that attach
(22). Install cockpit door assembly (2) on interior door handle assembly (47).
aircraft (Ref. Section 52-00-00). (11). Remove screws (35 and 36) that attach
exterior door handle (46), spacers (43)
(23). Ensure proper alignment and operation
and housing assembly (42) to door
of latch mechanism when reinstalled on
aircraft (Ref. Section 52-00-00, Cockpit frame.
Door Rigging Verification - Original B. Door Latch Mechanism Installation (New
Configuration). Configuration
14. Door Latch Mechanism, Cockpit (New (Ref. Figure 401)
Configuration)
A. Door Latch Mechanism Removal (New
(Ref. CSPSPM)
Configuration)
Item Nomenclature
(Ref. Figure 401) C239 Sealant
NOTE: Left and Right side latch mechanisms
are typical. NOTE: Left and Right side latch mechanisms
are typical.
(1). Remove cockpit door assembly (2) (Ref.
Section 52-00-00). (1). Install screws (35 and 36) attaching
exterior door handle (46), housing
(2). Remove (interior) cockpit door panel assembly (42) and spacers (43) in door
(Ref. Section 25-10-00). frame.
(3). Remove and discard cotter pin (80). NOTE: Ensure handle will be in horizontal
Remove clevis pin (77) and washers (78 position with respect to aircraft when door is
and 79) that attach clevis (67), exten installed on aircraft.
Page 409
(2). Install screws (44 and 45) attaching NOTE: Verify protrusion by pushing the bolt in
interior door handle assembly (47). and confirming that there is no more than
0.010 in. (0.254 mm) of play.
attaching both upper and lower latch (15). Adjust connecting tube (76) so that
block assemblies (40) to door. bottom attachment hole lines up with
hole on clevis (67).
(16). Install clevis pin (77), washers (78 and
cotter pin (66) attaching clevis (67) to
79) and cotter pin (80) connecting clevis
housing assembly (42) bellcrank.
(67), extension spring (71) and connect
(5). Assemble turnbuckle rod (60), hex nut ing tube (76).
(57) and clevis (58). (17). Ensure all cotter pins are installed and
bent.
(6). Rotate handle (47) to the fully closed
SAFELOCK (horizontal) position. (18). Install (interior) cockpit door panel
(7). Attach clevis (67) to turnbuckle rod
(60). (19). Verify condition and security of strikes
(81) to fuselage door frame.
(20). Install cockpit door assembly (2) on
lower latch block (40).
(9). Loosen hex nut (57) and adjust turn of latch mechanism when reinstalled on
buckle rod (60) so that bolt in lower aircraft (Ref. Section 52-00-00, Cockpit
latch block (40) protrudes fully (full Door Rigging Verification - New
LOCK position). Configuration).
NOTE: This can be verified by pushing the bolt 15. Cockpit Door Window
in and confirming that there is no more than
0.010 in. (0.254 mm) of play. A. Window Removal
Sealant (C239) (Ref. Figure 401)

(1). Carefully remove window (26) from
around inside edge of window seal (32)
and door frame.
(2). Remove window (26).
(10). Apply sealant (C239) and tighten hex
nut (57). B. Window Installation
(11). Install extension spring (71) onto door (Ref. Figure 401)
using spacer (74), screw (72) and NOTE: If old window seal is soft and workable,
washer (73). install window with loop of string method. If
seal is hardened or dry from age, remove old
(12). Assemble clevis (75) and connecting
seal and replace (Ref. Section 52-00-00).
tube (76) together.
(1). Install string around inside periphery
(13). Install clevis pin (68), washer (69) and of window seal (32).
upper latch block (40). (2). With window pressed against seal (32),
slowly pull string out of seal allowing
(14). Push connecting tube (76) up so that window (26) to slip under lip of seal.
bolt of upper latch block (40) protrudes Continue process until entire window
fully (full LOCK position). edge slips under lip of seal.
Page 410
16. Window Seal, Cockpit Door (2). Install new window seal (32) around
edge of window (26) transparency.
A. Seal Removal
(Ref. Figure 401) (3). Mask off window (26) transparency to
(1). Peel seal (32) from around inside edge minimize contact from squeeze out of
of door frame while removing window silicone compound (C221).
(26).
B. Seal Installation Silicone Compound (C221)
(Ref. Figure 401)
(Ref. CSPSPM)
Item Nomenclature (4). Apply silicone compound (C221) around
C221 Silicone Compound door frame that mates to surface of
C420 Solvent, Cleaning seal. Spread evenly using small brush.
Solvent, Cleaning (C420) (5). Install window (26) with seal (32) into
door frame and press down edges to
ensure even contact of surfaces.
(6). Apply weight or pressure to window

(1). Clean old sealant from around door surface. For adhesive to fully cure
frame and clean surface with cleaning requires 7 days.
solvent (C420).
Page 411
26
2
25
25
35
36 1 32
81
25
81 14
15
12
29
6
8 27 28
13
16
24
11
7
16
5
4
3
14
15
30 11
23
6 12
27
20 13
22
31
24
33
21 7
17 5 10
18 4
33 3
19 9
34
9G52-007-1
Figure 401. Cockpit Door/Window Assembly (Sheet 1 of 4)
Page 412
38 (4 PL)
37 (4 PL)
48
40
53
48 54
57 58 55 47
52
49
41 44
38 (2 PL) 39 (2 PL)
41 53
54
38 (4 PL) 55
48 50 45
51
39 (4 PL)
35
48 42
57
63 56
53
61 54
55 36
62 43 59 (REF)
52
46 VIEW LOOKING DOWN
59
60
53
LOCK POSITION
54
55
57 SLAM POSITION
57 OPEN POSITION
58
ORIGINAL CONFIGURATION
53
54
55
38 (4 PL)
37 (4 PL)
40
9G52-007-2
Page 413
70
69 REF 75
NOTE
40
37 (4 PL) NEW CONFIGURATION

75 68 38 (4 PL)
NOTE
UPPER AND LOWER LATCH
BLOCKS ARE TYPICAL
76
72 67
73 60 57
REF 71
74 71
58
A
REF 76 77 40
78
A
68
69
70
79
80
47
REF 67 44
35
42 45
65
66
46 43 (2 PL)
36
VIEW A-A
64
NOTE: REPLACE EXISTING SCREWS AND WASHERS

AT THESE LOCATIONS TO FILL HOLES.
9G52-007-3
Page 414
11
85
12
83
82
84
86
VIEW LOOKING INBOARD
9G52-007-4
Page 415

1. DOOR LATCH MECHANISM 44. SCREW
2. COCKPIT DOOR ASSEMBLY 45. SCREW
3. COTTER PIN 46. EXTERIOR DOOR HANDLE
4. NUT 47. INTERIOR DOOR HANDLE
5. WASHER 48. HEX FITTING
6. BOLT 49. CABLE ASSEMBLY
7. BUSHING 50. CLEVIS PIN
8. HINGE MECHANISM 51. COTTER PIN
9. GAS STRUT 52. LINK
10. STRUT BRACKET 53. CLEVIS PIN
11. PULL ROD ASSEMBLY 54. WASHER
12. RETAINING BOSS 55. COTTER PIN
13. DOOR FORK ASSEMBLY 56. CLEVIS ASSEMBLY
14. RIVETS 57. HEX NUT
15. FLANGED HOUSING 58. CLEVIS
16. DOOR RELEASE HANDLE 59. CLEVIS
17. NUT 60. TURNBUCKLE ROD
18. WASHER 61. CLEVIS PIN
19. DOOR RELEASE STOP BRACKET 62. SPACER
20. DOOR RELEASE SHAFT 63. RETURN SPRING
21. RIVET 64. CLEVIS PIN
22. SPRING PIN 65. WASHER
23. DOOR RELEASE FLANGED FITTING 66. COTTER PIN
24. RIVET 67. CLEVIS
25. DOOR SEAL 68. CLEVIS PIN
26. WINDOW 69. WASHER
27. RETAINER 70. COTTER PIN
28. SPACER 71. EXTENSION SPRING
29. SPACER 72. SCREW
31. DOOR RESTRAINT END FITTING 74. SPACER
32. WINDOW SEAL 75. CLEVIS
33. PIVOT POST BALL FITTING 76. CONNECTING TUBE
34. RETAINING SPRING CLIP 77. CLEVIS PIN
35. SCREW 78. WASHER
36. SCREW 79. WASHER
37. SCREW 80. COTTER PIN
38. WASHER 81. STRIKE
39. SCREW 82. SNAP PIN
40. LATCH BLOCK ASSEMBLY 83. REMOVABLE RESTRAINT ASSEMBLY
41. SUPPORT PLATE ASSEMBLY 84. QUICK RELEASE PINS
42. HOUSING ASSEMBLY 85. LANYARD
43. SPACER 86. LANYARD
17. Cabin Door Assembly B. Cabin Door Assembly Installation

(Ref. Figure 402)
A. Cabin Door Assembly Removal
(1). Put cabin door on door tracks and move
(Ref. Figure 402) forward.
(2). Install door stops and quick release
(1). Open cabin door (2). pins.
18. Door Upper Fitting Components

(2). Remove quick release pins (3 and 40)
and door stops (4 and 41). A. Door Upper Fitting Components Removal
(Ref. Figure 402)
(3). Move cabin door (2) aft and remove
from upper and lower tracks (5). (1). Remove cabin door.
Page 416
(2). Remove pin rivet or bolt (39), washers B. Lower Aft Cabin Door Link Installation
(12 and 32), and post (34). Remove
track roller (35). (Ref. Figure 402)
B. Door Upper Fitting Components Consumable Materials

Installation (Ref. CSPSPM)
Item Nomenclature
(Ref. Figure 402) C107 Grease, Aircraft
Consumable Materials Grease, Aircraft (C107)

(Ref. CSPSPM)
Item Nomenclature
C310 Primer
(1). Install bushings, use aircraft grease

NOTE: (C107).
Washers can be added or removed be (2). Put link in its installed position and
tween post and track roller to get full en install bolt (14), washers, bushing, and
gagement of track rollers in door track. nut. Torque nut.
If quantity of washers is changed, pin riv (3). Install bolt (8), washers, bushing, and
et or bolt length must also be changed. nut. Torque nut.
Make sure track rollers move freely in 20. Lower Aft Carriage
door track.
A. Lower Aft Carriage Removal
(1). Install post in track roller.
(Ref. Figure 402)
Primer (C310) (1). Remove cabin door.
(2). Remove nut (11), washers (12 and 13),
bolt (14), and bushing (15).
(3). Remove carriage (30).
(2). Apply primer (C310) to mating surfaces B. Lower Aft Carriage Installation
of post and upper washer.
(Ref. Figure 402)
(3). While primer is wet, install pin rivet or
bolt, washers, and post with track Consumable Materials
roller. (Ref. CSPSPM)
Item Nomenclature
(4). Install cabin door. C107 Grease, Aircraft
19. Lower Aft Cabin Door Link

A. Lower Aft Cabin Door Link Removal
(Ref. Figure 402)
(1). Remove nut (6), washers (7), bolt (8), (1). Install bushing, use aircraft grease
and bushing (9). (C107).
(2). Put carrage in its installed position.
bolt (14), and bushing (15). Remove link (3). Install bolt, washers, and nut. Torque
(10). nut.
Page 417
(4). Install cabin door. B. Horizontal Track Roller Installation

(Ref. Figure 402)
21. Vertical Lower Aft Carriage Track Roller
A. Vertical Track Roller Removal
(Ref. CSPSPM)
Item Nomenclature
(Ref. Figure 402)
C310 Primer
(1). Remove cabin door.
post (34), and pin rivet or screw or bolt Primer (C310)
(31). Remove track roller (35).
B. Vertical Track Roller Installation
(Ref. Figure 402) (2). Apply primer (C310) to mating surfaces

of post and carrage.
Consumable Materials (3). While primer is wet, install pin rivet or

(Ref. CSPSPM) screw, washer(s), post with track roller,
Item Nomenclature and nut. Torque nut.
C310 Primer (4). Install cabin door.
23. Cabin Door Fairing
(1). Install post in track roller. A. Cabin Door Fairing Removal
Primer (C310) (Ref. Figure 402)

(1). Remove rivets (16).
(2). Remove fairing (17).
B. Cabin Door Fairing Installation
(2). Apply primer (C310) to mating surfaces
of post and carriage. Consumable Materials
(Ref. CSPSPM)
(3). While primer is wet, install post with Item Nomenclature
track roller, pin rivet or screw or bolt, C310 Primer
washers, bushing, and nut. Torque nut.
(1). Put fairing in its installed position.
(4). Install cabin door.
Primer (C310)
22. Horizontal Lower Aft Carriage Track
Roller
A. Horizontal Track Roller Removal

(2). Install rivets, install wet with primer
(Ref. Figure 402) (C310).
24. Cabin Door, Door Stop
A. Door Stop Removal
(2). Remove nut (11), washer (32) if
(Ref. Figure 402)
installed, washer (33), post (37), and
pin rivet or screw (36). (1). Remove quick release pins (3 and 40).
Page 418
(2). Remove door stops (4 and 41) and Grease, Aircraft (C107)
bushings (28 and 27).
B. Door Stop Installation
(Ref. Figure 402)

(1). Apply aircraft grease (C107) to bush
(1). Install bushings in door stops. ing.
(2). Install door stops. (2). Put pivot lug in its installed position.
(3). Install quick release pins. (3). Install bushing, pin rivet, washers, and
nut. Torque nut.
25. Cabin Door Stop Pad (4). Install cabin door.
A. Stop Pad Removal 27. Pivot Lug Vertical Track Roller
(Ref. Figure 402) A. Pivot Lug Vertical Track Roller Removal
(1). Remove lower aft cabin door link. (Ref. Figure 402)
(2). Remove nut (20), washer (19), and bolt (1). Remove cabin door.
(18). Remove stop pad (21).
(2). Remove nut (11), washer (32) if
B. Stop Pad Installation installed, washer (33), post (34), and
pin rivet or screw or bolt (31). Remove
(Ref. Figure 402) track roller (35).
(1). Install bolt, stop pad, washer, and nut. B. Pivot Lug Track Vertical Roller
Torque nut. Installation
(2). Install lower aft cabin door link. (Ref. Figure 402)
26. Lower Forward Cabin Door Pivot Lug Consumable Materials

(Ref. CSPSPM)
A. Pivot Lug Removal
Item Nomenclature
(Ref. Figure 402) C310 Primer

(2). Remove nut (24), pin rivet (25), wash
ers (12), and bushing (26). Remove Primer (C310)
pivot lug (29).
B. Pivot Lug Installation
(Ref. Figure 402) (2). Apply primer (C310) to mating surfaces

of post and pivot lug.
(Ref. CSPSPM)
(3). While primer is wet, install pin rivet or
Item Nomenclature
screw or bolt, washer(s), post with track
roller, and nut. Torque nut.
Page 419
28. Pivot Lug Horizontal Track Roller (4). Remove screws (55 and 56), washers
(54), bolts (48 and 69), and support
A. Pivot Lug Horizontal Track Roller plates (57 and 70).
Removal
(Ref. Figure 402) Remove washers (44) and clevis pins
(50). Disconnect tubes (46 and 47).
(6). Remove tubes (46 and 47).
(2). Remove pin rivet or screw (31), washer
(32) if installed, post (34), and spacer (7). Remove screws (58 and 59) and
(38). Remove track roller (35). washers (54). Remove inner door
handle (60).
B. Pivot Lug Horizontal Track Roller
Installation
Remove clevis pin (52). Disconnect tube
(Ref. Figure 402) (53).
(9). Remove clevis (66) and nut (67).
Consumable Materials (10). Remove and discard cotter pin (49).
(Ref. CSPSPM) Remove washer (44) and clevis pin (50).
Item Nomenclature Disconnect tube (53).
C310 Primer
(11). Remove tube (53).
(12). Remove screws (63 and 64), outer door
(1). Install post in track roller. handle (61), and handle housing (62).
Primer (C310) (13). Remove screws (65), washers (54), and
bellcrank (51).
strike plates (71 and 72).
(2). Apply primer (C310) to mating surfaces B. Door Latch Mechanism Installation and
of spacer and pivot lug. Rigging
(3). While primer is wet, install pin rivet or (Ref. Figure 402)
screw, washer if installed, post with
track roller, and spacer. Torque pin Consumable Materials
rivet or screw. (Ref. CSPSPM)
Item Nomenclature
C239 Sealant
29. Cabin Door Latch Mechanism (EARLY
CONFIG) (1). Put bellcrank in its installed position.
Install screws and washers. Torque
A. Door Latch Mechanism Removal
screws.
(Ref. Figure 402) (2). Put outer door handle and handle
NOTE: Left and right latch mechanisms are housing in their installed position,
typical. install screws. Torque screws.
(3). Install clevis and nut in tube (53) with
(1). Remove cabin door. approximately one half of clevis in tube.
(2). Remove cabin door trim panel (Ref. Do not tighten nut at this time.
Section 25-20-00). (4). Put tube (53) in its installed position.
(3). Remove and discard cotter pins (43). (5). Connect tube (53) to handle housing
Remove washers (44) and clevis pins assembly and install clevis pin, washer,
(45). and cotter pin.
Page 420
(6). Adjust clevis on tube (53) until bell (22). Put inner door handle in its installed
crank is at approximately a 30 degree position and install screws and wash
angle. Do not tighten nut at this time. ers. Torque screws.
(7). Install clevis pin and cotter pin. (23). Turn inner handle clockwise to SAFE
LOCK position.
(8). Put tube (46) in its installed position.
(24). Make a measurement of the distance
(9). Install clevis in tube (46) with approxi top bolt extends above door frame.
mately one half of clevis in tube. Dimensions must be 1.15 in (38 mm).
(25). Make a measurement of the distance
(10). Connect tube (46) to bellcrank and
bottom bolt extends below door frame.
install clevis pin, washer, and cotter
Dimensions must be 1.28 in. (32.5 mm).
pin. Do not bend ends of cotter pin at
this time. (26). If necessary, adjust tube (53) to get the
correct dimensions.
(11). Put top bolt and support plate in their
installed positions. Install screws and Sealant (C239)
washers. Torque screws.
(12). Connect tube (46) to top bolt. Install

clevis pin, washer, and cotter pin.
(27). Apply sealant (C239) to threads of
(13). Adjust clevis in tube (46) until top bolt
clevis and torque nut.
extends 1.15 in. (38 mm) above door
frame. (28). Put upper strike plate in its installed
position and install screws and wash
(14). When adjustment is correct, connect ers. Torque screws.
tube (46) and install clevis pin, washer,
and cotter pin. (29). Put lower strike plate in its installed
position and install screws and wash
(15). Put tube (47) in its installed position. ers. Torque screws.
(16). Install clevis in tube (47) with approxi (30). Install cabin door trim panel (Ref.
mately one half of clevis in tube. Section 25-20-00).
(17). Connect tube (47) to bellcrank and (31). Install cabin door.
install clevis pin, washer, and cotter (32). Do the Cabin Door Rigging Verification
pin. Do not bend ends of cotter pin at procedure.
this time.
(33). Do the Cabin Door Operational Test
(18). Put bottom bolt and support plate in procedure.
their installed position. Install screws
and washers. Torque screws. 30. Cabin Door Bolting System (CURRENT
CONFIG)
(19). Connect tube (47) to bottom bolt.
Install clevis pin, washer, and cotter (Ref. Figure 403)
pin.
NOTE: Left and right latch mechanisms are
(20). Adjust clevis in tube (47) until bottom typical.
bolt extends 1.28 in. (32.5 mm) below
A. Bolting System Removal
door frame.
(21). When adjustment is correct, connect
tube (47) and install clevis pin, washer, (2). Remove cabin door trim panel (Ref.
and cotter pin. Section 25-20-00).
Page 421
(3). Remove screws (28). (3). Turn handle to SAFELOCK position.

(4). Remove screws (27), washers (3), (4). Install clevis in tube (9) with approxi
escutcheon (26), and inner handle (). mately one half of clevis in tube.
(5). Put tube (9) in its installed position.
Remove washer (11) and clevis pin (13). (6). Connect tube (9) to handle housing and
Disconnect tube (21) from bellcrank (1). Install clevis pin, washer, and cotter
pin.
(6). Remove rod end (22) and nut (23)
(7). Adjust clevis in tube (9) until bellcrank
(7). Remove and discard cotter pin (12). will be approximately 80 degrees from
Remove washer (11) and clevis pin (19). horizontal.
Disconnect tube (21) from bolt (24).
(8). Connect tube (9) to bellcrank and
(8). Remove screws (16 and 17), washers install clevis pin, washer, and cotter
(3), bottom bolt (24), and support plate pin.
(25). (9). Put tube (18) in door.
(9). Remove tube (21). (10). Install rod end and nut in tube (18)
with approximately one half of rod end
(10). Remove and discard cotter pin (12). in tube. Do not tighten nut at this time.
Remove washer (11) and clevis pin (13).
Disconnect tube (18) from bellcrank (1). (11). Connect tube (18) to bellcrank and
install clevis pin, washer, and cotter
(11). Remove rod end (20) and nut (23). pin. Do not bend ends of cotter pin at
this time.
Remove washer (11) and clevis pin (19). (12). Install top bolt, support plate, screws,
Disconnect tube (18) from bolt (14). and washers. Torque screws.
(13). Remove screws (16 and 17), washers (13). Connect tube (18) to top bolt and install
(3), top bolt (14), and support plate (15). clevis pin, washer, and cotter pin.
(14). Adjust rod end in tube (18) until top
(14). Remove tube (18). bolt extends 1.28 in. (32.5 mm) above
(15). Remove and discard cotter pin (12). door frame. Torque nut.
Remove washer (11) and clevis pin (13). (15). When adjustment is correct, connect
Disconnect tube (9) from bellcrank (1). tube (18) and install clevis pin, washer,
and cotter pin.
Remove washer (11) and clevis pin (10). (16). Put tube (21) in door.
Disconnect tube (9) from handle (17). Install rod end and nut in tube (21)
housing (4). with approximately one half of rod end
(17). Remove tube (9). in tube.
(18). Install lower bolt, support plate,
(18). Remove screws (6 and 7), handle (5), screws, and washers. Torque screws.
and handle housing (4).
(19). Connect tube (21) to lower bolt and
(19). Remove screws (2), washers (3), and install clevis pin, washer, and cotter
bellcrank (1). pin.
B. Bolting System Installation and Rigging (20). Adjust rod end in tube (21) lower bolt
extends 1.36 in. (34.5 mm) below door
(1). Install bellcrank, screws, and washers. frame.
Torque screws.
(21). When adjustment is correct, connect
(2). Install handle housing, handle, and tube (21) and install clevis pin, washer,
screws. Torque screws. and cotter pin.
Page 422
(22). Install escutcheon, screws, and wash Grease, Fluorosilicone (C121)

ers. Torque screws.
NOTE: Red dot on inner handle should point
aft when handle is in SAFELOCK position.
(23). Turn handle to SAFELOCK position.
(24). Make a measurement of the dimension
top bolt extends above door frame. (2). Apply fluorosilicone grease (C121) to
Dimension must be 1.28 in. (32.5 mm). window seal.
(25). Make a measurement of the dimension
bottom bolt extends below door frame.
Dimension must be 1.36 in. (34.5 mm). NOTE: Keep pressure applied to lower rear cor
(26). If necessary, adjust tube (9) to get the ner of window during installation.
correct dimension.
(27). Install cabin door trim panel (Ref. (3). Put window in seal, start at lower rear
Section 25-20-00).
corner.
(29). Do the Cabin Door Latch Mechanism
Rigging Verification procedure. (4). Lift seal over edge of window along rear
vertical edge, then upper horizontal
(30). Do the Cabin Door Operational Test
procedure. edge, then lower horizontal edge, and
then forward vertical edge. Use a blunt
31. Cabin Door Window (non-metallic) tool.
(Ref. Figure 402)
Consumable Materials (5). Make sure window edge is fully in seal.

(Ref. CSPSPM)
Item Nomenclature
C121 Grease, Fluorosilicone NOTE: If window is not fully in seal, move seal
in and out along edge of door.
A. Window Removal
(1). Push on the lower forward external (6). Apply a force of 50 lbs (22.68 Kg) to
corner of cabin window (22) until corner center of inner side of window. No
pops out of seal (23) on internal side. openings between seal and window
(2). Keep pressure near point window is permitted on inner or outer side of
still engaged in seal, push window out window.
of seal.
(3). Remove seal.
(7). Apply a force of 25 lbs (11.34 Kg) to
B. Window Installation
center of outer side of window. No
NOTE: Smooth door seal on door frame by hand openings between seal and window
to get full length of seal on frame. permitted on inner or outer side of
(1). Install window seal on door frame. window.
Page 423
32. Cabin Door Fitting fitting (74).

(Ref. Figure 402) B. Cabin Door Fitting Installation
Primer (C310)
(Ref. CSPSPM)
Item Nomenclature
C310 Primer
(1). Put cabin door fitting in its installed
A. Cabin Door Fitting Removal position. Install screws, install wet with
primer (C310). Torque screws 12-15
(1). Remove screws (73). Remove cabin door in-lb (1.36-1.69 Nwm).
Page 424
5
2
22
23 1
22
5
23
17
3 5 16
4 17
28
25
31
32
39 12
35 35
40 32 34 34
5
12 12 38
34
42 26 31
12
33
41 24 11
29 35 32
27
9G52-008-1C
Figure 402. Cabin Door/Window With EARLY CONFIG Latch Mechanism (Sheet 1 of 2)
Page 425
14
73 (4 PL)
12
15 31 LEFT SIDE SHOWN
10 74
6 13
7 32
8
9 35
20 34
19 33
11
37
11 35
33 32
21 18 12
30 11
36
71
59 59
54 56
54
48 57 59
58 60
55 4 PL
54
54
45
43
44
46 63 61
44 64
53 49
62
47
44
68 50
45
43
46 65
69 55 68 54
54 50 50
51
70 44 44
49 49
59 56 52
54 54 43 53
72 68
66 67 47
9G52-008-2D
Figure 402. Cabin Door/Window With EARLY CONFIG Latch Mechanism (Sheet 2 of 2)
Page 426

1. DOOR LATCH MECHANISM (EARLY CONFIG) 38. SPACER
2. CABIN DOOR 39. PIN RIVET OR BOLT
3. QUICK RELEASE PIN 40. QUICK RELEASE PIN
4. DOOR STOP 41. DOOR STOP
5. DOOR TRACK 42. DOOR UPPER FITTING
6. NUT 43. COTTER PIN
8. BOLT 45. CLEVIS PIN
9. BUSHING 46. TOP CONNECTING TUBE
10. LINK 47. BOTTOM CONNECTING TUBE
11. NUT 48. TOP BOLT
12. WASHER 49. COTTER PIN
13. WASHER 50. CLEVIS PIN
14. BOLT 51. BELLCRANK
15. BUSHING 52. CLEVIS PIN
16. RIVET 53. CENTER CONNECTING TUBE
17. LOWER FAIRING 54. WASHER
18. BOLT 55. SCREW
20. NUT 57. TOP SUPPORT PLATE
21. STOP PAD 58. SCREW
22. WINDOW 59. SCREW
23. WINDOW SEAL 60. INTERIOR DOOR HANDLE
24. NUT 61. EXTERIOR DOOR HANDLE
25. PIN RIVET 62. HANDLE HOUSING
26. BUSHING 63. SCREW
29. PIVOT LUG 66. CLEVIS
30. LOWER AFT CARRIAGE 67. JAM NUT
31. PIN RIVE OR SCREW OR BOLT 68. CLEVIS
32. WASHER (EARLY CONFIG) 69. BOTTOM BOLT
33. WASHER 70. BOTTOM SUPPORT PLATE
34. POST 71. UPPER STRIKE PLATE
35. TRACK ROLLER 72. LOWER STRIKE PLATE
36. PIN RIVET OR SCREW 73. SCREW
37. DOOR POST 74. CABIN DOOR FITTING
Page 427
17 ( 2 PL)
3 ( 2 PL)
16 ( 4 PL ) 5
3 ( 4 PL )
6
12
7
14 12 11
15
19
18 ( REF ) 18 ( REF )
11
9
8 10 4
18
23 1 26
13
20
12 28 ( 2 PL )
13 11
12
2 (3 PL)
3 (3 PL) 11 9 ( REF )
12 13
11 9 ( REF )
22
23
21
21 ( REF )
11 19
12
25 29
27 ( 4 PL )
3 ( 4 PL )
16 ( 4 PL )
3 ( 4 PL )
24
17 ( 2 PL)
3 ( 2 PL)
9G52-015A
Figure 403. Cabin Door Bolting System (CURRENT CONFIG)
Page 428

1. BELLCRANK 16. SCREW
2. SCREW 17. SCREW
3. WASHER 18. TUBE
4. HANDLE HOUSING 19. CLEVIS PIN
5. OUTER HANDLE 20. ROD END
6. SCREW 21. TUBE
7. SCREW
22. ROD END
8. CLEVIS
23. NUT
9. TUBE
10. CLEVIS PIN 24. LOWER BOLT
11. WASHER 25. SUPPORT PLATE
12. COTTER PIN 26. ESCUTCHEON
13. CLEVIS PIN 27. SCREW
14. UPPER BOLT 28. SCREW
15. SUPPORT PLATE 29. INNER HANDLE
33. Baggage Door Assembly 34. Door Strut Assembly

A. Door Strut Assembly Removal
A. Baggage Door Assembly Removal
(Ref. Figure 404)
(Ref. Figure 404) (1). Remove nut (5), washer (3) and bolt (8)
that attach door strut assembly (16) to
(1). Disengage baggage door latch mecha strut bracket hinge half (31).
nism (19). (2). Remove strut assembly (16).
(2). Support door weight and remove nut B. Door Strut Assembly Installation
(5), washers (2, 3 and 4) and bolt (1) (Ref. Figure 404)
that join upper fuselage hinge (28) and
upper door hinge (29). (1). Install bolt (8), washer (3) and nut (5)
attaching door strut assembly (16) to
(3). Remove nut (5), washers (2, 3 and 7) strut bracket hinge half (31).
and bolt (6) that join lower spoiler
35. Strut Bracket Hinge Half
hinge (34) and lower door hinge (35).
A. Strut Bracket Hinge Half Removal
(4). Remove baggage door assembly (30). (Ref. Figure 404)
B. Baggage Door Assembly Installation (1). Remove door strut assembly (16) (Ref.
Section 52-00-00).
(Ref. Figure 404) (2). Remove hinge pin (32) that attaches
strut bracket hinge half (31) to struc
tural hinge butt (33).
(1). Align baggage door assembly (30) with
upper and lower door hinge halves. (3). Remove hinge (31).
B. Strut Bracket Hinge Half Installation
(2). Install bolt (1), washers (2, 3 and 4) and
nut (5) joining upper door hinge (29) (Ref. Figure 404)
and upper fuselage hinge (28).
(1). Cut hinge pin (32) 0.22 - 0.28 in. (5.58
- 7.11 mm) shorter than hinge (31).
(3). Install bolt (6), washers (2, 3 and 7) and
nut (5) joining lower spoiler hinge (34) (2). Align hinge halves and install hinge pin
and lower door hinge (35). (32) and center within body of hinge.
Page 429
(3). Install door strut assembly (16) (Ref. (7). Remove nut (51) and washers (49 and
Section 52-00-00). 50) that attach bellcrank (47) to crank
spindle.
36. Strut Bracket
A. Strut Bracket Removal bolts (66) that attach exterior handle
assembly (48).
(Ref. Figure 404)
(1). Remove nut (11), washers (10) and bolts (21) that attach mounting bracket
screws (9) that attach strut bracket (12) assembly (42) to door assembly (30).
to door assembly (30). B. Door Latch Mechanism Installation
(2). Remove bracket (12). (Ref. Figure 404)
B. Strut Bracket Installation
(Ref. Figure 404) (Ref. CSPSPM)
Item Nomenclature
(1). Align strut bracket (12) with mounting C239 Sealant
holes in baggage door assembly (30).
(2). Install screws (9), washers (10) and nut (1). Install washers (44) and nuts (45)
(11) attaching bracket (12) to door attaching stop studs (43) to mounting
assembly (30). bracket assembly (42).
37. Door Latch Mechanism, Baggage (2). Install bolt (69), washer (44) and nut
(45) attaching pawl (46) to bellcrank
A. Door Latch Mechanism Removal (47).
(Ref. Figure 404) (3). Install bolts (21), washers (20) and nuts
(22) attaching mounting bracket
(1). Remove baggage door assembly (Ref. assembly (42) to door assembly (30).
Section 52-00-00).
(2). Remove door trim panel (Ref. Section (68) attaching exterior handle assembly
25-50-00). (48).
(3). Remove and discard cotter pins (62). (5). Install washers (49 and 50) and nut
Remove washers (61) and clevis pins (51) attaching bellcrank (47) to crank
(60) that attach upper and lower spindle.
connecting tubes (52) to bellcrank (47). NOTE:
(4). Remove upper and lower bolt rod Position upper support block (23) with
assemblies (53 and 54) from bolt guide thin edge up and lower support block (24)
assemblies (19). with thin edge down.
Use washers (18) if required such that top
(5). Remove and discard cotter pins (57). and bottom bolt rods will be in contact
Remove washers (56) and clevis pins with aft face of striker plates, and door
(55) that attach rod ends (63) to upper outer mold line is flush with shell within
and lower bolt rod assemblies (53 and 0.030 in. (0.762 mm). Also ensure that
54). bolt rods are in contact with inboard face
of striker plates by adjusting striker
(6). Remove nuts (14), washers (2 and 18) plates.
and bolts (17 and 36) that attach upper
and lower support blocks (23 and 24) (6). Install bolts (17 and 36), washers (2
and guide assemblies (19) to door and 18) and nuts (14) attaching upper
assembly (30). and lower support blocks (23 and 24)
Page 430
and bolt guide assemblies (19) to door (17). Insert bolt rod assembly (54) into lower
(30). guide assembly (19).
(7). Thread rod end (63) and hex nut (64) (18). Install clevis pin (60), washer (61) and
into upper end of connecting tube cotter pin (62) attaching upper end of
assembly (52). Do not tighten hex nut connecting tube (52) to bellcrank (47).
at this time. (19). Rotate rod end (63) in connecting tube
(52) until 19.60 0.50 in. (49.78 1.27
(8). Install clevis pin (55), washers (56) and
cm) dimension, measured from center
cotter pin (57) attaching rod end (63) to
of handle (48) to end of bolt rod (54),
upper bolt rod assembly (53).
will be obtained while connecting tube
(9). Install washer (58) and compression (52) is connected to bellcrank (47).
spring (59) on bolt rod assembly (53). Ensure that flat end of rod end
CAUTION (63) is parallel with flat end of
(10). Insert bolt rod assembly (53) into upper connecting tube (52) before tightening hex
guide assembly (19). nut (64). Failure to do so will result in inter
ference with door bolting system operation.
cotter pin (62) attaching lower end of Sealant (C239)
connecting tube (52) to bellcrank (47).
(12). Rotate rod end (63) in connecting tube

(52) until 18.40 - 19.40 in. (46.73 -
49.27 cm) dimension, measured from (20). Apply sealant (C239) to threads of rod
center of handle (48) to end of bolt rod end (63) and tighten hex nut (64).
(53), will be obtained while connecting
tube (52) is connected to bellcrank (47). NOTE: Nominal bolt travel is 1.34 in. (3.40
cm) for upper bolt (53) and 1.13 in. (2.87
Ensure that flat end of rod end cm) for lower bolt (54).
CAUTION (63) is parallel with flat end of
connecting tube (52) before tightening hex (21). Rotate handle (48) from SAFELOCK
nut (64). Failure to do so will result in inter to OPEN position. Operation shall be
ference with door bolting system operation. smooth and positive.
Sealant (C239)
(22). Install door trim panel (Ref. Section
25-50-00).
(23). Install baggage door assembly (Ref.
Section 52-00-00).
(13). Apply sealant (C239) to threads of rod of latch mechanism when reinstalled on
end (63) and tighten hex nut (64). aircraft (Ref. Section 52-00-00,
Baggage Door Rigging Verification).
(14). Thread rod end (63) and hex nut (64)
into end of lower connecting tube 38. Lower Hinges, Door and Spoiler
assembly (52). Do not tighten hex nut
at this time. A. Lower Hinge Removal
(15). Install clevis pin (55), washers (56) and (Ref. Figure 404)
cotter pin (57) attaching rod end (63) to (1). Remove door assembly (30) (Ref.
lower bolt rod assembly (54). Section 52-00-00).
(16). Install washer (58) and compression (2). Remove bolts (38) and washers (37)
spring (65) on lower bolt rod assembly that attach lower door hinge (35), lower
(54). spoiler hinge (34) and shims (27).
Page 431
(3). Remove hinges (34 and 35) and shims (2). Remove nuts (14), washers (2) and bolts
(27). (39 and 40) that attach upper fuselage
hinge (28) and shims (25).
B. Lower Hinge Installation
(Ref. Figure 404) (3). Remove hinge (28) and shims (25).
(1). Align hinges (34 and 35) and shims (27) B. Upper Fuselage Hinge Installation
and install washers (37) and bolts (38)
attaching lower door hinge (35) and (Ref. Figure 404)
lower spoiler hinge (34).
(2). Install door assembly (30) (Ref. Section (1). Align hinge (28) and shims (25) and
52-00-00) install bolts (39 and 40), washers (2)
and nuts (14).
39. Upper Hinge, Door
(2). Install door assembly (30) (Ref. Section
A. Upper Door Hinge Removal 52-00-00).
(Ref. Figure 404)
41. Hinge Stop
(1). Remove door assembly (30) (Ref.
Section 52-00-00). A. Hinge Stop Removal
(2). Remove nuts (14), washers (2) and bolts
(38) that attach upper door hinge (29) (Ref. Figure 404)
and shims (26).
(1). Remove upper fuselage hinge (28).
(3). Remove hinge (29) and shims (26).
(2). Remove rivets (71) that attach hinge
B. Upper Door Hinge Installation
stop (70) to hinge (28).
(Ref. Figure 404)
B. Hinge Stop Installation
(1). Align hinge (29) and shims (26) and
install bolts (38), washers (2) and nuts (Ref. Figure 404)
(14).
(2). Install door assembly (30) (Ref. Section NOTE: Locate hinge stop such that a minimum
52-00-00). clearance of 0.10 inch (2.54 mm) is main
tained between the baggage door and the aft
40. Upper Hinge, Fuselage fuselage when the door is in the open posi
tion.
A. Upper Fuselage Hinge Removal
(Ref. Figure 404) (1). Install rivets (71) attaching hinge stop
(70) to upper fuselage hinge (28)
(1). Remove door assembly (30) (Ref.
Section 52-00-00). (2). Install fuselage hinge (28).
Page 432
60 46 69 60
61 44 61
62 68 (2 PL) 45 62
67 (2 PL) 43 (2 PL)
66 (2 PL)
42 52
52 47
44 (2 PL)
45 (2 PL)
48
3 14
5
33 2
30
17 41 2
36 9 16 15
32
19
31
8
53
59 23
65
57 2 14
18
58
21 51 9
56 10
55 50
49 12
56
10
20 42
63 11
52
64
20 22
52 REF
47
17
18
24 14
2
54
9G52-009-1A
Figure 404. Baggage Door Assembly (Sheet 1 of 2)
Page 433
14
2
13
25
28
2 14
40 2
14
39 70
71
1
2
4 2
38
2 25
29 3 5
26
26
27
6
2
2
14
3
34 37 38
5
27 35 38
37
9G52-009-2B
Figure 404. Baggage Door Assembly (Sheet 2 of 2)
Page 434

1. BOLT 37. WASHER
2. WASHER 38. BOLT
3. WASHER 39. BOLT
4. WASHER 40. BOLT
5. NUT 41. DOOR SEAL
6. BOLT 42. MOUNTING BRACKET ASSEMBLY
7. WASHER 43. STOP STUD
8. BOLT 44. WASHER
9. SCREW 45. NUT
10. WASHER 46. PAWL
11. NUT 47. BELLCRANK
12. STRUT BRACKET 48. EXTERIOR HANDLE ASSEMBLY
13. STRUT EYEBOLT 49. WASHER
14. NUT 50. WASHER
15. GUIDE PIN
51. NUT
16. DOOR STRUT ASSEMBLY
52. CONNECTING TUBE ASSEMBLY
17. BOLT
53. UPPER BOLT ROD ASSEMBLY
18. WASHER
54. LOWER BOLT ROD ASSEMBLY
19. BOLT GUIDE ASSEMBLY
55. CLEVIS PIN
20. WASHER
56. WASHER
21. BOLT
57. COTTER PIN
22. NUT
23. UPPER SUPPORT BLOCK 58. WASHER
24. LOWER SUPPORT BLOCK 59. COMPRESSION SPRING
25. UPPER SHIM, FUSELAGE 60. CLEVIS PIN
26. UPPER SHIM, DOOR 61. WASHER
27. LOWER SHIM 62. COTTER PIN
28. UPPER FUSELAGE HINGE 63. ROD END
29. UPPER DOOR HINGE 64. HEX NUT
30. DOOR ASSEMBLY 65. COMPRESSION SPRING
31. STRUT BRACKET HINGE HALF 66. BOLT
32. HINGE PIN 67. WASHER
33. STRUCTURAL HINGE BUTT 68. NUT
34. LOWER SPOILER HINGE 69. BOLT
35. LOWER DOOR HINGE 70. HINGE STOP
36. BOLT 71. RIVET
42. Door Seal Silicone Compound (C221)

A. Door Seal Removal
(Ref. Figure 404)
(1). Remove baggage door assembly (30)
Fluorosilicone Compound (C222)
(2). Remove door seal (41).
B. Door Seal Installation
(Ref. Figure 404)
(1). Install door seal (41) using silicone
Consumable Materials compound (C221) and fluorosilicone
(Ref. CSPSPM) compound (C222). Complete cure of
Item Nomenclature compound takes 7 days.
C221 Silicone Compound
C222 Fluorosilicone Compound (2). Install baggage door assembly (30)
Page 435
43. Baggage Door Switch E. Baggage Door Switch (CURRENT

CONFIG) Removal
A. Baggage Door Switch (EARLY CONFIG)
(Ref. Figure 405) (1). Remove screws (17) and disconnect wire
harness.
(1). Remove screws (10) and disconnect wire
harness. (2). Remove nuts (18), lock washers (19),
(2). Remove nuts (9), lock washers (8), washers (11), and screws (12). Remove
washers (2), and screws (3). Remove switches (20) and switch actuator (21).
switch (7). F. Baggage Door Switch (CURRENT
B. Baggage Door Switch (EARLY CONFIG) CONFIG) Installation
Installation
(Ref. Figure 405)
(Ref. Figure 405)
(1). Put switches and switch actuator in
(1). Put switch in its installed position and their installed position and install
install screws, washers, lock washers, screws, washers, lock washers, and
and nuts. Torque nuts 3 in-lb (0.34 nuts. Torque nuts 3 in-lb (0.34 Nwm).
Nwm).
(2). Connect wire harness and install
(2). Connect wire harness and install screws. Torque screws 4 in-lb (0.45
screws. Torque screws 4 in-lb (0.45 Nwm).
Nwm).
(3). Do the baggage door switch adjust
(3). Do the baggage door switch adjust ment.
ment.
G. Baggage Door Switch Bracket (CURRENT
C. Baggage Door Switch Bracket (EARLY CONFIG) Removal
CONFIG) Removal
(Ref. Figure 405)
(Ref. Figure 405)
(1). Remove baggage door switch.
(1). Remove baggage door switch.
(2). Remove screws (6), washers (5), and (2). Remove nuts (16), washers (14), if
spacer washers (4) if installed. Remove installed spacer washers (15), and
bracket (1). screws (13). Remove bracket (22).
D. Baggage Door Switch Bracket (EARLY H. Baggage Door Switch Bracket (CURRENT
CONFIG) Installation CONFIG) Installation
(1). Put bracket in its installed position and (1). Put bracket in its installed position and
install screws, washers, and if neces install screws, washers, if necessary
sary spacer washers. Torque screws. spacer washers, and nuts. Torque nuts.
(2). Install baggage door switch. (2). Install baggage door switch.
Page 436
10 (3 PL)
9 (2 PL)
8 (2 PL)
19 (2 PL)
2 (2 PL)
18 (2 PL) 11 (2 PL)
20
7 1
21
2 (2 PL
17 (6 PL)
22
16 (2 PL)
3 (2 PL)
14 (2 PL)
11 (2 PL)
4 (2 PL)
12 (2 PL) (NOTE)
15 (4 PL)
(NOTE) EARLY CONFIG
5 (2 PL)
6 (2 PL)
14 (2 PL)
13 (2 PL) CURRENT CONFIG
9G52-017
NOTE:
IF NECESSARY TO GET THE CORRECT ADJUSTMENT, ADD WASHERS BETWEEN BRACKET AND HELICOPTER STRUCTURE.
1. BRACKET 12. SCREW

2. WASHER 13. SCREW
3. SCREW 14. WASHER
4. SPACER WASHER 15. SPACER WASHER
5. WASHER 16. NUT
6. SCREW 17. SCREW
7. SWITCH 18. NUT
8. LOCK WASHER 19. LOCK WASHER
9. NUT 20. SWITCH
10. SCREW 21. SWITCH ACTUATOR
11. WASHER 22. BRACKET
Figure 405. Baggage Door Switch
Page 437
Page 438
DOORS AND WINDOWS

INSPECTION/TEST/RIGGING VERIFICATION
1. Doors/Windows damage is evident, replace components
A. Doors/Windows Inspection
(a). Cabin Door - Inspect vertical
(Ref. Figure 601) movement of door latch pin with door
(1). Inspect all doors (crew, cabin and handle in closed (SAFE LOCK)
baggage) for general condition, smooth position. Refer to rigging verification
operation and security. If binding or procedure for movement limitations
some form of restriction is evident, and adjustment instruction.
localize problem and replace damaged (b). Cabin Door - Inspect upper and
or worn components (Ref. Section lower latch pin for proper protrusion
52-00-00). No damage allowed. in closed (SAFE LOCK) position.
(2). Inspect all door attaching hardware for Refer to rigging verification proce
security of installation and presence of dure for dimensions and adjustment
locking devices. If locking device is instruction.
missing, check fastener connection for
(9). Inspect handles and locks for security
specific torque value (if applicable) and
and proper operation. No damage
install new locking device. Replace any
allowed. If looseness or play is exces
damaged or worn hardware. No sive, replace component (Ref. Section
damage allowed.
52-00-00).
(3). Inspect hinge mechanisms and attach
(10). Inspect door seals for deterioration,
points for general condition and
cuts or damage that would reduce their
security. Ensure that areas are free
sealing ability. If seals are damaged
from cracks, scoring, corrosion or any
beyond functional usefulness, replace
other form of deterioration. No damage
seal (Ref. Section 52-00-00).
allowed. If damage is evident, replace
component. (11). Inspect all windows for cracks,
scratches and obstructions to vision.
(4). Inspect crew door gas struts for security
Maximum depth of a scratch is 0.030
and proper operation. No damage
inch (0.762 mm), 6 inches (15.24 cm)
allowed. Replace strut if damaged (Ref.
Section 52-00-00). in length with a minimum spacing of
0.50 inch (12.7 mm) between. The
(5). Verify that door release mechanism on same criteria applies to all areas of
crew door is secure and EXIT decal is both crew and cabin windows.
legible and secure.
NOTE: Minor defects or imperfections that do
(6). Inspect rollers on cabin doors for not impair pilots critical visibility, or that
excessive wear, binding or scoring. No obviously are not signs of impending struc
damage allowed. Replace as soon as tural failure may be considered as negligi
possible if restriction or deterioration is ble.
evident (Ref. Section 52-00-00).
(12). Inspect all window seals for cracking,
(7). Inspect cabin door stops for security. No splitting or any other forms of deterio
damage allowed. If damaged, replace ration. None allowed.
(13). Inspect cabin door pull-out window
(8). Inspect door latching mechanisms for (emergency exit) for cracking and
functional operation, excessive wear, general condition. No cracks allowed.
cracks and/or corrosion at contact Verify that EXIT decal is legible and
locations. No damage allowed. If any secure.
Page 601
(14). Visually inspect window retainer for (b). Apply a force of 25 lbs. centrally to
cuts, cracks, or signs of deterioration. the outside of door window. There
No damage allowed. Replace if dam shall be no visual sign of seal break
aged (Ref Section 52-00-00). ing away from window all around on
(a). Apply a force of 50 lbs. centrally to both sides.
the inside of door window. There
shall be no visual sign of seal break
ing away from window all around on
both sides.
EMERGENCY EGRESS STRAP ATTACHMENT
CREW DOOR WINDOW CABIN DOOR WINDOW
NO CRACKS ARE ALLOWED AROUND THE AREA

OF THE EMERGENCY EGRESS STRAP ATTACHMENTS
(AREA CIRCLED).
9G52-012
Figure 601. Window Damage Limits

2. Doors Operational Test (5). Verify that key locks and unlocks door
handle.
A. Cockpit Doors Operational Test
(6). Verify outside door contacting area for
(1). Verify inside and outside door handle closure and alignment.
operates at all positions.
(7). Verify that door releases and opens
(2). Close and latch doors from inside and without restriction when handle is
inspect entire contacting surface areas turned to open position.
for even alignment. B. Cabin Doors Operational Test
(3). Verify that latching mating surfaces (Ref. Figure 603)
align properly and strike extends .0.325
+/- .010 inches into striker plate when NOTE: Test is typical for LH and RH cabin
closed and 0.450 +/- .010 inches when doors.
locked. (1). Verify upper and lower latch pins
(4). Observe that door is forced inward for engage door frame properly.
seal compression at each latch position. (2). Open and close door three times. Verify
door travel and operation of latching
(a). Unequal striking or latching may mechanism is smooth.
indicate latch assembly, strike
alignment or connector rods that (3). Close and lock door. Verify seals are in
extend strikes, are not properly contact with frame by visual transmit
adjusted. tance of light through gaps.
Page 602
(4). Rotate handle from SAFELOCK to (15). CURRENT CONFIG - Open door to
OPEN position using a torque wrench. 52 in. (132 cm) position. Ensure
Torque shall not exceed 75 in-lb (8.47 forward edge of door is aft of aft door
Nm). pillar.
(5). Rotate handle from OPEN to SAFE C. Baggage Door Operational Test
LOCK position using a torque wrench.
(1). Verify door handle at all positions for
Torque shall not exceed 75 in-lb (8.47
functional operation.
Nm).
(2). Close and latch door from outside and
(6). Rotate handle to KEYLOCK position. observe closure and positive locking as
Lock latching mechanism. handle is turned to SAFELOCK
(7). On outside door handle, apply a torque position.
of 50 in-lb (5.65 Nm) towards the (3). Verify that key locks and unlocks door
OPEN position. Handle shall remain in handle.
KEYLOCK position.
(4). Verify that door releases and opens
(a). EARLY CONFIG - Handle remains without restriction when handle is
downward approximately 80 DEG turned to open position.
from horizontal.
3. Door Latch Mechanism Rigging
(b). CURRENT CONFIG - Handle Verification
remains horizontal.
A. Cockpit Door Latch Mechanism Rigging
(8). On inside door handle, apply a torque of Verification Original Configuration
75 in-lb (8.47 Nm) towards the
OPEN position. Door shall unlatch. (Ref. Figure 602)
(1). With door open, rotate handle to fully
(9). Unlock latching mechanism. closed SAFELOCK position and check
(10). EARLY CONFIG - Unlatch door using position of bolts (no free play allowed).
outside handle. Pull door outward, but (2). Rotate handle to OPEN position to
do not slide aft. ensure that bolts are fully retracted (no
(a). Rotate handle to SLAM position. free play allowed) and release handle.
(3). Mechanism must move and stop at
(b). At inside door handle, pull door SLAM position (if not, adjust detent
closed using a 50 lb (22.68 kg) force. setscrews).
Door shall close shut.
NOTE: At this position, bolts should be able to
(11). Move door stops to aft positions. push in.
(a). EARLY CONFIG - 50 in. (127 cm). (4). Move handle to OPEN position and
clamp upper bolt to prevent it from
(b). CURRENT CONFIG - 52 in. protruding.
(132 cm).
(5). Rotate handle towards SAFELOCK
(12). Unlatch door, open and close door using position until it stops.
a force of 10 lb (4.54 kg). Door shall
move smoothly along full length of (6). Apply force to handle and observe if
track. there is any side load at link (1) and
clevis (2).
(13). Open door and engage hold open
mechanism. (7). If side load exists, and results in
sideways movement of clevis (2),
(14). Close door using a force of 30 lb eliminate it by loosening screws (3) on
(13.61 kg). Mechanism shall prevent cable support plate assembly (4) and
door from closing. move it to line up link (1) and clevis (2).
Page 603
(8). When adjustment is correct, tighten (3). CURRENT CONFIG - On bottom

screws (3) and remove clamp. latch pin, verify pin protrudes past
cover plate 1.36 in. (3.45 cm).
B. Cockpit Door Latch Mechanism Rigging
Verification New Configuration (a). Push up on bottom pin. Pin shall
move less than 0.05 in. (1.27 mm)
(Ref. Figure 602)
(b). On upper latch pin, verify pin
(1). With door open, rotate handle to fully protrudes past cover plate 1.28 in.
closed SAFELOCK position and check (3.25 cm).
position of bolts (no free play allowed). (c). Push down on upper pin. Pin shall
(2). Rotate handle to OPEN position to move less than 0.05 in. (1.27 mm).
ensure that bolts are fully retracted (no (4). Rotate handle in both directions. Action
free play allowed) and release handle. shall be smooth and positive.
(3). Mechanism must move and stop at (5). Rotate handle to OPEN position and
SLAM position (if not, adjust detent close door.
setscrews).
(6). Turn handle to SAFELOCK position,
NOTE: At this position, bolts should be able to door shall be secure.
push in.
(7). Turn handle to OPEN position, door
C. Cabin Door Latch Mechanism Rigging shall open easily.
Verification (8). Adjust latching mechanism as neces
sary to comply with verification
(Ref. Figure 603)
procedure. Refer to installation proce
NOTE: Verification procedure is typical for LH dure for rigging instructions
and RH cabin doors. (Ref. Section 52-00-00).
D. Baggage Door Latch Mechanism Rigging
(1). With door open, rotate handle to Verification
SAFELOCK position.
(Ref. Figure 603)
(2). EARLY CONFIG - On bottom latch
pin, verify pin protrudes past cover (1). With door installed on aircraft, rotate
plate 1.28 in. (2.92 cm). handle to SAFELOCK position.
Operation should be smooth and
(a). Push up on bottom pin. Pin shall positive. Bolt rod assemblies should
move less than 0.05 in. (1.27 mm). firmly engage mating strikes in
airframe.
(b). On upper latch pin, verify pin
protrudes past cover plate 1.15 in. (2). Rotate handle from SAFELOCK to
(3.25 cm). Open position. Operation should be
smooth and positive. Bolt rod assem
(c). Push down on upper pin. Pin shall blies should completely disengage
move less than 0.05 in. (1.27 mm). mating strikes in airframe.
Page 604
SAFE LOCK
(FLIGHT POSITION)
OPEN
4
SLAM 3
KEYLOCK
2
MAINTAIN A STRAIGHT
ALIGNMENT OF THESE TWO
ITEMS AT THE LOADING
POSITION WHEN THE BOLT
1 IS CLAMPED DOWN.

DETENT ADJUSTMENT

ORIGINAL CONFIGURATION
SETSCREW
9G52-014
1. LINK 3. SCREW
2. CLEVIS 4. CABLE SUPPORT PLATE
Figure 602. Cockpit Door Latch Mechanism Rigging Verification
Page 605
LATCH
PIN
UPPER
1.28 IN.
(3.25 CM)
(NOTE 1)
COVER
PLATE
COVER PLATE
1.36 IN.
LATCH PIN (3.45 CM)
BOTTOM (NOTE 1) SAFE LOCK
( FLIGHT POSITION )
LATCHING
POSITION 10 o 30
OPENED
POSITION
80 o TYP
TO CLOSE
80 o
SLAM
SAFE LOCK KEY LOCK

( FLIGHT POSITION )
KEY LOCK 160 o
EARLY CONFIGURATION
80 o TYP
TO OPEN
OPENED
POSITION
NOTES:
1. CURRENT CONFIG SHOWN. 9G52-013A
Figure 603. Cabin and Baggage Door Latch Mechanism Rigging Verification (Sheet 1 of 2)
Page 606
BOLT ROD
ASSEMBLY
BOLT ROD
ASSEMBLY
9G52-016
Figure 603. Cabin and Baggage Door Latch Mechanism Rigging Verification (Sheet 2 of 2)
Page 607
4. Baggage Door Switch Adjustment B. Baggage Door Switch Adjustment

(CURRENT CONFIG)
A. Baggage Door Switch Adjustment
(EARLY CONFIG)
(Ref. Figure 405)
(Ref. Figure 405)
Power On (1). Apply external electrical power to
helicopter (Ref. CSP-RMM-3, Section
96-00-00).
(2). Loosen nuts (18) and adjust switches

(1). Apply external electrical power to (20) until BAGGAGE DOOR caution
helicopter (Ref. CSP-RMM-3, Section light on IIDS stays on when door is not
96-00-00). in SAFELOCK. If necessary, add or
(2). Adjust switch (7) until BAGGAGE remove spacer washers (15). Torque
DOOR caution light on IIDS stays on nuts 3 in-lb (0.34 Nwm)
when door is not in SAFELOCK. If
necessary, add or remove spacer (3). Make sure BAGGAGE DOOR caution
washers (4). light on IIDS stays off when door is in
SAFELOCK.
(3). Make sure BAGGAGE DOOR caution
light on IIDS stays off when door is in
SAFELOCK. Power Off
Power Off
(4). Make sure all electrical power is

(4). Make sure all electrical power is
disconnected from helicopter (Ref.
disconnected from helicopter (Ref.
CSP-RMM-3, Section 96-00-00).
CSP-RMM-3, Section 96-00-00).
Page 608
DOORS AND WINDOWS

REPAIR
1. Doors / Windows Alcohol, Isopropyl (C419)
A. Cabin Door Window Water Leak Repair
(1). Clean area to be sealed with isopropyl

alcohol (C419) and dry.
(Ref. CSPSPM) Silicone Compound (C221)
Item Nomenclature

C419 Alcohol, Isopropyl (2). Apply silicone compound (C221) locally
as required to stop water leakage.

52-00-00 Revision 3
Chapter
FUSELAGE
TABLE OF CONTENTS
53-10-00 Windscreens and Nose Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A

1. Windscreens and Nose Area - General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Cockpit Screens Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
A. Cockpit Windscreens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
B. Windscreen Wipers (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
C. Chin Windscreens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
D. Windscreen Washer (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Figure 1.Windscreens and Nose Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
3. Cockpit Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
A. Cockpit Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Figure 2.Cockpit Installation and Cockpit Assembly . . . . . . . . . . . . . . . . . . . . . . . . 4
B. Cockpit Roof Skin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
C. Tub Forward Skins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
D. Lower Nose Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
E. Lower Fillets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
F. Landing Light Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
G. Attachment Angles, Cleats, and Reinforcing Strap . . . . . . . . . . . . . . . . . . . . . . . . . 5
H. Cockpit Upper Door Seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Fault Isolation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
1. Windscreen Wipers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
1. Windscreens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
A. Windscreen Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
B. Windscreen Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
Figure 201.Cockpit Windscreens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
Figure 202.Windscreen Repairs Zones . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
Table 201.Windscreen Allowable Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
C. Windscreen Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
2. Windscreen Wipers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
A. Wiper Blade Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
B. Wiper Blade Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
C. Wiper Arm Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
D. Wiper Arm Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
E. Wiper Link Removal (EARLY CONFIG) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
F. Wiper Link Installation (EARLY CONFIG) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
Page i

G. Wiper Link Removal (CURRENT CONFIG) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
H. Wiper Link Installation (CURRENT CONFIG) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
I. Wiper Arm Clamp Removal (EARLY CONFIG) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
J. Wiper Arm Clamp Installation (EARLY CONFIG) . . . . . . . . . . . . . . . . . . . . . . . . . . 205
K. Wiper Motor Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
L. Wiper Motor Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
M. Wiper Motor Mounting Bracket Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
N. Wiper Motor Mounting Bracket Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
O. Relay Panel Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
P. Relay Panel Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
Q. Windscreen Wiper Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
Figure 203.Windscreen Wiper Installation (Sheet 1 of 2) . . . . . . . . . . . . . . . . . . . . 207
Figure 204.Windscreen Wiper Relay Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210
R. Windscreen Wipers Rigging/Operational Check (EARLY CONFIG) . . . . . . . . . . . 211
S. Windscreen Wipers Rigging/Operational Check (CURRENT CONFIG) . . . . . . . 211
T. Wiper Arm Tension Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211
Figure 205.Windscreen Wiper Rigging/Operational Check . . . . . . . . . . . . . . . . . . 212
3. Landing Light Window Panel (N82) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213
A. Landing Light Window Panel Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213
B. Landing Light Window Panel Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213
C. Landing Light Window Panel Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213
4. Nose Access Door (N80) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213
A. Nose Access Door Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213
Table 202.Landing Light Window Allowable Repairs . . . . . . . . . . . . . . . . . . . . . . . 213
Figure 206.Landing Light Window Panel / Nose Access Door . . . . . . . . . . . . . . . . 214
B. Nose Access Door Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214
C. Nose Access Door Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214
53-20-00 Lower and Center Fuselage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A
1. Fuselage Lower and Center - General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Figure 1.Fuselage Lower and Center Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. General Tub Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
A. Access Panel and Covers Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
B. Fuel Cell Liner Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Figure 2.General Tub Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
C. Tub Shell Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Figure 3.Tub Shell Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Page ii

D. Cockpit Subfloor Support Structure Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Figure 4.Cockpit Subfloor Support Structure Assembly . . . . . . . . . . . . . . . . . . . . . 8
E. FS 155.50 Tub Bulkhead Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
F. Forward Skid Attachment Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
G. FS 155.50 Frame Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Figure 5.FS 155.50 Tub Bulkhead and Frame Assemblies,
Forward Skid Attachment Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
H. FS 230.50 Tub Bulkhead Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
I. FS 230.50 Lower Frame Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
J. Aft Skid Attachment Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
K. Cabin Door Frames Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
L. Boat Tail Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Figure 6.Aft Skid Attachment Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
M. Step Ribs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
N. Tie-Down Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
3. Side Skin Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
A. Side Skin Panel Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
B. Door Posts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
C. Fillets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
4. Cockpit Floor Panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
A. Composite Panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
B. Metallic Floor Panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
C. Kick Strips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Figure 7.Cockpit Floor Panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
5. Cabin Floor Panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
A. Composite Panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
B. Metallic Panels and Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
C. Seat Tracks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
D. Kick Strips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
E. Cabin Door Fillets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Figure 8.Cabin Floor Panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
6. Baggage Floor Panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
A. Outboard Baggage Floor Panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
B. Center Tie-Down Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
C. Aft Tie-Down Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
D. Tie-Down Rings, Clips, and Studs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Figure 9.Baggage Floor Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Page iii

7. Cockpit Console Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
A. Console Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
8. Cabin Door Track . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
9. Work Platform Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Figure 10.Work Platforms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
1. Lower Center And Aft Fuselage Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
A. Airframe Continued Airworthiness Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
B. Floor Panel Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
C. Fuselage Exterior Panel Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
D. Fuselage Cockpit Area Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
E. Fuselage Cabin Area Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
Figure 201.Cockpit, Cabin and Baggage Compartment Floor Panels . . . . . . . . . 202
F. Aft Fuselage Area and Baggage Compartment Inspection . . . . . . . . . . . . . . . . . . . 203
2. Cockpit Outboard Left Floor Panel (AL129) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
A. Cockpit Outboard Left Floor Panel Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
B. Cockpit Outboard Left Floor Panel Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
3. Cockpit Outboard Right Floor Panel (AR129) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
A. Cockpit Outboard Right Floor Panel Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
B. Cockpit Outboard Right Floor Panel Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
4. Cockpit Floor Access Panels (AL138 and AR138) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
A. Cockpit Floor Access Panels Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
B. Cockpit Floor Access Panels Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
Figure 202.Cockpit Floor Panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
5. Cabin Floor Forward And Aft Access Covers (AL155, AR155, AL230 and AR230) 206
A. Cabin Floor Access Cover Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
B. Cabin Floor Access Covers Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
6. Cabin Floor Outboard Panels (AL165 and AR165) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
A. Cabin Floor Outboard Panel Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
B. Cabin Floor Outboard Panel Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
7. Cabin Floor Forward Panel Assembly (A160) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
A. Cabin Floor Forward Panel Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
B. Cabin Floor Forward Panel Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
8. Cabin Floor Center Panel (A170) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208
A. Cabin Floor Center Panel Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208
B. Cabin Floor Center Panel Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208
9. Cabin Floor Aft Panel Assembly (A217) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209
Page iv

A. Cabin Floor Aft Panel Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209
B. Cabin Floor Aft Panel Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209
Figure 203.Cabin Floor Panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210
10. Baggage Floor Center Panel (A235) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210
A. Baggage Floor Center Panel Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210
B. Baggage Floor Center Panel Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211
11. Baggage Floor Outboard Panels (AL250 and AR250) . . . . . . . . . . . . . . . . . . . . . . . . . . 211
A. Baggage Floor Outboard Panels Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211
B. Baggage Floor Outboard Panels Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211
Figure 204.Baggage Compartment Floor Panels . . . . . . . . . . . . . . . . . . . . . . . . . . . 212
12. Cabin Step (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212
A. Cabin Step Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212
B. Cabin Step Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212
13. Cabin Step Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213
A. Cabin Step Plug Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213
B. Cabin Step Plug Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213
Figure 205.Cabin Step (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214
53-30-00 Fuselage Upper Deck and Aft Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A
1. Fuselage Lower, Center, and Aft Area - General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Roof Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Figure 1.Fuselage Upper Deck and Aft Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Figure 2.Roof Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
A. Roof Structure Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
B. Engine Deck, Aft Deck, and Aft Outer Deck Skins . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Figure 3.Roof Structure Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
C. A-Frame Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Figure 4.A-Frame Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
D. Forward Roof Structure Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
E. Mid Roof Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
F. Aft Deck Structure Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
G. Roof Beam Installations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Figure 5.Roof Structure Beam and Frame Assembly . . . . . . . . . . . . . . . . . . . . . . . 12
H. FS 230.50 Aft Frame Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Figure 6.FS 230.50 Upper Aft Frame Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
3. Firewall Build-Up Assembly and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
A. Firewall Build-Up Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Page v

4. Engine Deck Thermal Insulation Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
5. Anti-Torque Fan Inlet Duct Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Figure 7.Firewall Build-Up Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
A. Anti-Torque Fan Forward Duct Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
B. Anti-Torque Fan Aft Duct Assembly and Installation . . . . . . . . . . . . . . . . . . . . . . . 17
C. Anti-Torque Fan Diffuser-Stator and Diverter Plate Installation . . . . . . . . . . . . 18
Figure 8.Forward Duct, Aft Duct, Anti-Torque Diffuser-Stator,
and Diverter Plate Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
D. Anti-Torque Fan Support Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
E. Tailboom Attachment Ring Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Figure 9.Anti-Torque Fan Support Structure, Aft Duct Assembly,
and Tailboom Attachment Ring Assembly . . . . . . . . . . . . . . . . . . . . . . . 21
Figure 10.Rear Fuselage Shell Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
F. Rear Fuselage Shell Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Figure 11.Baggage Door Frame Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
6. Baggage Door Frame Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
A. Baggage Door Frames . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
B. Splice Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
C. Baggage Door Kick Strips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
D. Striker Plates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
7. Forward Fairings and Doors Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
A. Swashplate Fairing Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
B. Forward Fairing Support Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
C. Fixed Panel Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
D. Forward Access Door Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
E. Transmission Access Door Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Figure 12.Forward Fairings and Doors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
8. Aft Cowling and Fairing Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
A. Engine Cowl Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
B. Exhaust Ejector Cowl Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
C. Tailboom Upper Fairing Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Figure 13.Aft Engine Cowling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
1. Forward Access Door Assembly (L155, R155) and
Transmission Access Door Assembly (L210, R210) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
A. Access Door Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
B. Access Door Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
Figure 401.Access Door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 402
Page vi

2. Access Door Strut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 402
A. Access Door Strut Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 402
B. Access Door Strut Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 402
C. Access Door Strut Bracket Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 403
D. Access Door Strut Bracket Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 403
Figure 402.Access Door Strut and Strut Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . 404
3. Access Door Striker (EARLY CONFIG) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 405
A. Access Door Striker Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 405
B. Access Door Striker Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 405
Figure 403.Access Door Strikers (EARLY CONFIG) . . . . . . . . . . . . . . . . . . . . . . . . 406
4. Forward Fairing Support Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 407
A. Forward Fairing Support Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 407
B. Forward Fairing Support Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 407
Figure 404.Forward Fairing Support Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 408
5. Fixed Panel Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 408
A. Fixed Panel Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 408
B. Fixed Panel Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 408
Figure 405.Fixed Panel Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 409
6. Fixed Panel Bracket Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 409
A. Fixed Panel Bracket Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 409
B. Fixed Panel Bracket Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 409
7. Oil Cooler Air Outlet Screen Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 410
A. Oil Cooler Air Outlet Screen Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 410
B. Oil Cooler Air Outlet Screen Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . 410
8. Swashplate Forward Fairing Assembly (T155) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 410
A. Swashplate Forward Fairing Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . 410
B. Swashplate Forward Fairing Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . 411
Figure 406.Swashplate Forward and Aft Fairings . . . . . . . . . . . . . . . . . . . . . . . . . . 412
9. Swashplate Aft Fairing Assembly (T220) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 412
A. Swashplate Aft Fairing Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 412
B. Swashplate Aft Fairing Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 413
10. Engine Cowl Assembly (L260, R260) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 413
A. Engine Cowl Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 413
B. Engine Cowl Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 413
Figure 407.Engine Cowl Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 414
11. Exhaust Ejector Cowl Assembly (L270, R270) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 414
A. Exhaust Ejector Cowl Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 414
Page vii

B. Exhaust Ejector Cowl Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 414
Figure 408.Exhaust Ejector Cowl Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 415
12. Engine Upper Inlet Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 415
A. Engine Upper Inlet Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 415
B. Engine Upper Inlet Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 415
Figure 409.Engine Upper Inlet Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 416
13. Anti-Torque Inlet Screen Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 417
A. Inlet Screen Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 417
B. Inlet Screen Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 417
14. Upper Inlet Duct Assembly (T240) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 417
A. Inlet Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 417
B. Inlet Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 417
15. Middle Inlet Duct Assembly (F4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 417
A. Middle Inlet Duct Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 417
B. Middle Inlet Duct Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 418
Figure 410.Upper and Middle Inlet Duct Assemblies . . . . . . . . . . . . . . . . . . . . . . . 419
16. Forward Duct Assembly, Anti-Torque Fan (F1, F2 and F3) . . . . . . . . . . . . . . . . . . . . 420
A. Forward Duct Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 420
B. Forward Duct Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 421
Figure 411.Forward Duct and Fairing / Centerbody, Anti-Torque Fan . . . . . . . 423
17. Aft Duct Assembly, Anti-Torque Fan (F6, F7, and F8) . . . . . . . . . . . . . . . . . . . . . . . . 424
A. Lower Center Diffuser and Access Panel Removal . . . . . . . . . . . . . . . . . . . . . . . . . . 424
B. Upper Center Diffuser Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 424
C. Upper Center Diffuser Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 424
D. Lower Center Diffuser and Access Panel Installation. . . . . . . . . . . . . . . . . . . . . . . . 424
Figure 412.Aft Duct Assembly, Anti-Torque Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . 425
18. Diverter Plate and Aft Diffuser Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 426
A. Diverter Plate and Aft Diffuser Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 426
B. Diverter Plate and Aft Diffuser Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 426
Figure 413.Diverter Plate and Aft Diffuser Assembly . . . . . . . . . . . . . . . . . . . . . . . 428
Inspection/Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601
1. Fuselage Upper Deck and Aft Area Inspections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601
A. Fuselage Upper Deck Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601
B. Fuselage Aft Area Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601
2. Latch and Striker Adjustment (EARLY CONFIG) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601
A. Cowling Latch Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601
Figure 601.Cowling Latch Adjustment (EARLY CONFIG) . . . . . . . . . . . . . . . . . . 602
Page viii

B. Access Door Striker Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 602
Figure 602.Access Door Striker Adjustment (EARLY CONFIG) . . . . . . . . . . . . . 603
3. Anti-Torque Fan Diffuser Stator Vane Inspection (Area 6) . . . . . . . . . . . . . . . . . . . . 604
Table 601.Anti-Torque Fan Stator Vane Damage Limits . . . . . . . . . . . . . . . . . . . 604
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 801
1. Access Door Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 801
A. Cowling Latch Replacement (EARLY CONFIG) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 801
Figure 801.Cowling Latch Replacement (EARLY CONFIG) . . . . . . . . . . . . . . . . . 802
B. Forward Access Door Seal Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 802
C. Transmission Access Door Seal Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 803
Figure 802.Transmission Access Door and Forward Access Door Seals . . . . . . . 804
2. Support Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 804
A. Support Assembly Duct Frame Seal Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . 804
Figure 803.Support Assembly Duct Frame Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 805
3. Swashplate Aft Fairing Assembly (T220) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 806
A. Oil Dipstick Handhold Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 806
Figure 804.Oil Dipstick Handhold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 807
4. Engine Cowl Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 808
A. Engine Cowl Insulation Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 808
Figure 805.Engine Cowl Insulation Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . 809
53-40-00 Tailboom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A
1. Tailboom - General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Tailboom Bumper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
3. Tailboom/Thruster Fairing Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Figure 1.Tailboom Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
A. Tailboom Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
B. Tailboom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
C. Thruster Extension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
D. Slat Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
E. Upper and Lower Airfoils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
F. Slot Vanes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
G. Upper and Lower Inlet Ramps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
H. Forward Coaxial Cover, Aft Coaxial Cover, and Aft Wiring Cover . . . . . . . . . . . . 4
I. Fuselage Attachment, Empennage Attachment Frames, and Intercostals . . . . . 4
J. Vortex Generators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Figure 2.Tailboom Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Page ix


1. Tailboom Inspections (Area 7) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
A. Tailboom Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
Figure 201.Tailboom Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
B. Tailboom Bumper Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
Figure 202.Tailboom Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
2. Tailboom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
A. Tailboom Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
B. Tailboom Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
Figure 203.Tailboom/Thruster and Extension Fairings . . . . . . . . . . . . . . . . . . . . . 208
3. Lower Tailboom/Thruster Fairing Assembly (S2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209
A. Lower Tailboom/Thruster Fairing Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . 209
B. Lower Tailboom/Thruster Fairing Assembly Installation . . . . . . . . . . . . . . . . . . . . 209
4. Upper Tailboom/Thruster Fairing Assembly (SL1, SR1) . . . . . . . . . . . . . . . . . . . . . . . 209
A. Upper Tailboom/Thruster Fairing Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . 209
B. Upper Tailboom/Thruster Fairing Assembly Installation . . . . . . . . . . . . . . . . . . . . 209
5. Thruster Extension Fairing Assembly (SL8, SR8) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209
A. Thruster Extension Fairing Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209
B. Thruster Extension Fairing Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . 209
Figure 204.Tailboom Bumper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210
6. Tailboom Bumper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211
A. Tailboom Bumper Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211
B. Tailboom Bumper Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211
Figure 205.Vortex Generator Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212
7. Vortex Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213
A. Vortex Generator Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213
B. Vortex Generator Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213
Figure 206.Thruster Extension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214
8. Thruster Extension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215
A. Thruster Extension Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215
B. Thruster Extension Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215
Figure 207.Tailboom Secondary Details . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216
9. Tailboom Slot Vane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217
A. Tailboom Slot Vane Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217
B. Tailboom Slot Vane Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217
10. Tailboom Inlet Ramp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218
A. Tailboom Inlet Ramp Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218
Page x

B. Tailboom Inlet Ramp Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218
11. Tailboom Coaxial Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219
A. Tailboom Forward Coaxial Cover Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219
B. Tailboom Forward Coaxial Cover Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219
C. Tailboom Aft Coaxial Cover Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220
D. Tailboom Aft Coaxial Cover Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220
E. Tailboom Aft Wiring Cover Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220
F. Tailboom Aft Wiring Cover Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221
53-55-00 Empennage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A
1. Empennage - General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Horizontal Stabilizer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
A. Horizontal Stabilizer Bonded Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
B. Lower Structural Skin Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
C. Inboard and Outboard Rib . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
D. Empennage Attach Fitting and Intercostal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
E. Journal Housings and Journal Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
F. Attach Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
3. Elastomeric Damper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
4. Endplate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
A. Endplate Body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
B. Endplate Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
C. Closeout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
D. Tip Cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
E. Trailing Edge Tab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
5. Fairing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Figure 1.Empennage (Sheet 1 of2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1. Empennage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
A. Empennage Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
B. Empennage Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
2. Elastomeric Damper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 402
A. Elastomeric Damper Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 402
B. Elastomeric Damper Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 402
Figure 401.Empennage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 403
3. Stabilizer Outboard Fairing (SR3,SL3) (Stabilizer) . . . . . . . . . . . . . . . . . . . . . . . . . . . 404
A. Stabilizer Outboard Fairing (SR3,SL3) Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . 404
Page xi

B. Stabilizer Outboard Fairing (SR3,SL3) Installation . . . . . . . . . . . . . . . . . . . . . . . . . 404
Figure 402.Stabilizer Outboard Fairing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 404
4. Upper and Lower Horizontal Endplates (Vertical Stabilizer) . . . . . . . . . . . . . . . . . . . 405
A. Endplate Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 405
Figure 403.Horizontal Endplates (Vertical Stabilizer) . . . . . . . . . . . . . . . . . . . . . . 405
B. Endplate Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 405
Inspection / Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601
1. Empennage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601
A. Empennage Inspection (Area 7) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601
B. Endplate Inspection (Area 7) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601
C. Endplate Spar Tube Inspection (Area 7) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601
D. Elastomeric Damper Condition Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601
Figure 601.Endplate Spar Tube Bearing Journal Measurement . . . . . . . . . . . . . 602
Figure 602.Elastomeric Damper Condition Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . 602
Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 801
1. Journal Bearing Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 801
A. Journal Bearing Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 801
B. Journal Bearing Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 801
Figure 801.Journal Bearing Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 802
2. Access Panel Gaskets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 802
A. Gasket Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 802
Page xii
Section
531000
Windscreens and
Nose Area
WINDSCREENS AND NOSE AREA

1. Windscreens and Nose Area General B. Windscreen Wipers (Option)
(Ref. Figure 1) The windscreen wiper option installs wind
The windscreens and nose area of the fuselage screen wipers onto the pilots and copilots
located forward of FS 155.50 and above WL windscreens. Hardcoat Windscreens are
106.00, forms the forward cockpit enclosure for required for wiper installation and operation.
the crew.
EARLY CONFIG - The windscreen wipers
Two major installations are included in this are controlled by a rotary switch located on the
area, the cockpit installation and the cockpit console.
windscreens installation. The cockpit installa
tion installs the structural components for the CURRENT CONFIG - The windscreen
cockpit enclosure, and the cockpit windscreens wipers are controlled by a toggle swich located
installation installs the transparencies. on the console and relays installed in the
console on the right-hand side.
2. Cockpit Screens Installation
C. Chin Windscreens
(Ref. Figure 1)
The left and right chin windscreens are
The cockpit windscreens installation installs
stretched acrylic transparencies located in the
four transparencies onto the structure of the
forward, lower quadrants of the cockpit. The
cockpit assembly. The four transparencies are
windscreens are mounted onto the framework
the left and right cockpit windscreens, and the
of the cockpit assembly by machine screws,
left and right chin windscreens.
packings, washers and self locking nuts.
A. Cockpit Windscreens
D. Windscreen Washer (Option)
The left and right cockpit windscreens are
stretched acrylic transparencies located in The windscreen washer option provides
front of each crew station. The windscreens pressurized washer fluid to the windscreen
are mounted to the framework of the cockpit through four spray nozzles. The washer pump
assembly by machine screws, packings, and reservoir are located behind access panel
washers and self-locking nuts. N80.
Page 1
COCKPIT
INSTALLATION
RH COCKPIT
WINDSCREEN
RH CHIN
WINDSCREEN
LH COCKPIT
WINDSCREEN
COCKPIT
WINDSCREENS
INSTALLATION
LH CHIN
WINDSCREEN
9G53-026
Figure 1. Windscreens and Nose Area

3. Cockpit Installation A. Cockpit Assembly
The cockpit assembly includes the cockpit and
chin windscreens, landing light window, and
(Ref. Figure 2)
nose access door assembly. The major compo
nents of the cockpit assembly are the cockpit
The cockpit installation installs the cockpit roof structure, center pillar, chin bow assem
structure that supports the transparencies and bly, left and right door pillar assemblies,
the cockpit doors. Major components included battery box panels, and nose access door
in this installation are the cockpit assembly, assembly. Secondary components include
cockpit roof skin, tub forward skins, lower nose various attachment angles, brackets, plates,
panel, lower fillet components, aircraft battery and straps.
compartment, and the chin bow sill. Additional Cockpit Roof Structure The cockpit roof
components include attachment angles and structure is primary structure that supports
cleats, a reinforcing strap, and various seals. the upper edges of the cockpit windscreens.
Page 2
Original 53-10-00
The cockpit roof structure attaches the upper structure and to the tub shell of the general
portion of the cockpit assembly to the center tub assembly. Fastening is by rivets.
section of the fuselage. The cockpit roof
structure is fastened to the center pillar and The chin bow assembly is made up of an outer
the left and right door pillars, the FS 155.50 skin panel and left and right inner skin panels
frame assembly, and side skin assemblies of that are secondarily bonded together.
the general tub assembly. Fastening is by The outer skin panel is fabricated of graphite/
rivets. epoxy with barrier plies of fiberglass/epoxy. In
The cockpit roof structure is a composite the center of the panel above the opening for
sandwich panel. The panel incorporates the aircraft battery, the panel incorporates a
multiple plies of graphite/epoxy and a syntac section of Nomex honeycomb core cocured with
tic epoxy foam core. Around the periphery the the panel skin.
core terminates and the panel transitions to a Both the left and right inner skin panels are
monolithic laminate. fabricated using multiple plies of graphite/
Center Pillar The center pillar is a primary epoxy and fiberglass/epoxy cocured as mono
structural component that provides the lithic laminates.
attachment and structural support for the Door Pillars The left and right door pillar
inboard edges of the left and right cockpit assemblies are primary structural components
windscreens. The upper end of the pillar is that support the outboard edges of the cockpit
mechanically fastened to the cockpit roof and chin windscreens. These components
structure, and to the FS 155.50 frame assem attach, and are the door frames, for the left
bly of the general tub assembly. The lower end and right cockpit doors. Each door pillar is
of the pillar is secondarily bonded to the chin attached to the roof structure, chin bow
bow assembly. assembly, and forward tub skin by rivets.
The center pillar is `Ì shaped in cross section Each pillar assembly consists of an outer skin
and is fabricated as a composite sandwich and an upper and lower inner door pillar. All
panel with monolithic laminate flanges. The components are fabricated as monolithic
center section of pillar incorporates multiple laminates utilizing multiple plies of graphite/
plies of graphite/epoxy and fiberglass/epoxy epoxy and barrier plies of fiberglass/epoxy.
cocured with Nomex honeycomb and syntactic
epoxy foam cores. The cap flanges are mono Battery Box Panels The battery box panels
lithic and incorporate additional plies of are secondary structural components. One
graphite/epoxy. upper and two side battery box panels, are
fastened to each other and the interior surface
Chin Bow Assembly The chin bow assembly of the chin bow assembly using secondary
is a primary structural component. The angles and rivets. The panels are located
assembly provides support and provisions for adjacent at the cutout in the chin bow assem
attachment of the lower edges of the left and bly. Along the lower edges of the side panels,
right cockpit windscreeens, and the upper secondary angles are riveted to the panels
edges of the left and right chin windscreens. which in turn bolt to the battery floor assem
The assembly also attaches the nose access bly of the cockpit floor installation.
door assembly, the landing light window, and
battery box panels. The upper ends of the chin Each of the battery box panels is fabricated of
bow assembly are mechanically fastened to the multiple ply graphite/epoxy cocured with a
left and right door pillar assemblies. The lower Nomex honeycomb core. Around the periphery
portion of the assembly is mechanically of the panel, the core is tapered and the panel
fastened to the cockpit subfloor support transitions to monolithic laminate flanges.
Page 3
53-10-00 Original
CENTER PILLAR COCKPIT ROOF

SKIN
RH DOOR PILLAR
COCKPIT ROOF
STRUCTURE
CHIN BOW
ASSEMBLY
NOSE ACCESS
DOOR ASSEMBLY BATTERY
BOX
LANDING LIGHT PANELS TUB FORWARD SKIN
WINDOW (LH SHOWN, RH OPPOSITE) 9G53-041
Figure 2. Cockpit Installation and Cockpit Assembly
Nose Access Door Assembly The battery The mounting bracket and shim are fabricated
access door assembly is a secondary structural from aluminum alloy sheet. The hinges and
component that allows access to the battery turnlock fasteners and retaining rings are
box. The access door is hinge mounted at the standard hardware.
top to the chin bow assembly. In the closed
position, the access door is retained by two Attachment Angles, Brackets, Plates, and
quarter turn fasteners. Retention of the door Straps The attachment angles, brackets,
in the opened position is by a strut mounted on plates and straps are secondary structural
the chin bow assembly and a bracket mounted components that are used for attachment of
on the nose access door panel. components within the assembly. These
components are formed and fabricated from
The components included in the battery access aluminum alloy sheet and attached by rivets
door assembly are the battery access door, or pins and collars.
strut mounting bracket, hinges, a shim, and
quarter turn turnlock studs and retaining B. Cockpit Roof Skin
rings. The hinges and the strut mounting
The cockpit roof skin is a primary structural
bracket are fastened by rivets.
shear panel that supports the upper portion of
the cockpit assembly. This panel attaches to
A battery access door seal is bonded to the chin the roof structure of the cockpit assembly and
bow assembly. This provides an environmental to a flange on the FS 155.50 frame assembly of
seal for the battery compartment. the general tub assembly by rivets.
The access door is fabricated of multiple plies The cockpit roof skin is fabricated of multiple
of graphite/epoxy and barrier plies of fiber plies of graphite/epoxy and a barrier ply of
glass/epoxy cocured with a syntactic epoxy fiberglass/epoxy cocured with a syntactic epoxy
foam core. Around the periphery of the door, foam core. Around the periphery the panel
the panel transitions to a monolithic laminate. transitions to a monolithic laminate.
Page 4
Original 53-10-00
C. Tub Forward Skins E. Lower Fillets

The tub forward skins are primary structural The left and right lower fillets are secondary
components that support the lower outboard structural components that complete the joints
edges of the chin windscreens and attach the between the cockpit door pillars and the
lower nose panel. The left and right skins are cockpit sills. The fillets are fabricated from
attached to the lower portion of the cockpit aluminum alloy sheet and fastened with
assembly, the general tub assembly, the rivets.
plough beam assemblies, and the tub shell by
rivets.
The tub skins are fabricated as a monolithic F. Landing Light Window
laminate that incorporates multiple plies of
graphite/epoxy and barrier plies of fiberglass/ The landing light window is an acrylic
epoxy cocured as a monolithic laminate. transparency located on the forward, lower
Around the periphery the panel transitions to portion of the cockpit assembly. The window is
a monolithic laminate. A ply of Astrostrik
is installed with a seal between the window and
cocured to the exterior surface of the panel. the chin bow assembly. Retention of the
D. Lower Nose Panel window is by machine screws, packings,
washers and self locking nuts.
The lower nose panel is a secondary structural
shear panel. This panel is installed below the G. Attachment Angles, Cleats, and
landing light window between the left and Reinforcing Strap
right tub forward skins. This component is
attached to the tub forward skins, the plough The attachment angles, cleats, and reinforcing
beam assemblies, and the tub shell of the strap are secondary structural components.
general tub assembly by rivets. The lower nose These components are fabricated from
panel also attaches the lower edge of the aluminum alloy sheet and fastened by rivets
landing light window. and pins and collars.
The lower nose panel is fabricated of multiple H. Cockpit Upper Door Seals
plies of graphite/epoxy and barrier plies of
fiberglass/epoxy cocured with a syntactic epoxy The cockpit upper door seals are non-structur
foam core. Around the periphery the panel al components that provide the seal between
transitions to a monolithic laminate. A ply of the cockpit door and the cockpit door frame.
Astrostrik
is cocured to the exterior surface The upper cockpit door seals are rubber and
of the panel. are bonded to the land on each door pillar.
Page 5/(6 blank)

53-10-00 Original

FAULT ISOLATION
1. Windscreen Wipers The troubleshooting tables should be used
with the electrical wiring diagrams, service
ability checks and other detailed procedures in
The following troubleshooting procedures are a this and other chapters of the manual.
brief summary of winscreen wiper faults which Comprehensive wiring diagrams are available
may be encountered. in Section 98-40-00.
Both wipers do not operate in Faulty wiring Test and repair wiring 206000
any switch position
Faulty wiper switch Replace wiper switch 206000

Faulty relay (CURRENT Replace relay 206000
CONFIG)
Left or right wiper does not Faulty wiring Test and repair wiring 206000
operate in any switch position
Faulty circuit breaker Replace circuit breaker 206000

Faulty wiper switch Replace wiper switch 206000
Faulty relay (CURRENT Replace relay 206000
CONFIG)
Faulty wiper motor Replace wiper motor 531000

Left or right wiper does not Incorrect wiper arm tension Adjust wiper arm tension 531000
provide a clean sweep of the adjustment
windscreen
Left or right wiper operates Faulty wiring Test and repair wiring 206000
erratically, with or without
excessive noise
Incorrect torque on link to Torque hardware correctly 531000
clamp hardware

Left or right wiper operates Incorrect torque on link to Torque hardware correctly 531000
smoothly, with excessive clamp hardware
noise
Page 101
Page 102

1. Windscreens B. Windscreen Installation
A. Windscreen Removal (Ref. Figure 201)

(Ref. CSPSPM)
NOTE: Item Nomenclature
Removal of either cockpit and chin wind C207 Sealing Compound, Fuel Resistant
screens is typical.
Screw lengths vary at different locations NOTE: Installation of either cockpit and chin
around each windscreen. During removal windscreens is typical.
of windscreen, keep track of screw loca
tions by pressing the screws into a sheet (1). Position windscreen in frame and align
of cardboard in a pattern following the screw holes.
original hardware installation. (2). Install screws (2), packing washers (3),
flat washers (4) and nuts (5). Torque
(1). Mask windscreen (1). screws.
(2). Carefully cut and remove sealant from Sealing Compound (C207)
around windscreen.
(3). Remove screws (2), packing washers

(3), flat washers (4) and nuts (5) which
secure windscreen to airframe. (3). Apply sealing compound (C207) along
edges of windscreen.
(4). Lift windscreen from airframe, using
care to prevent damage to seal bond (4). After sealant has cured, remove
surfaces. masking.
Page 201
53-10-00 Original
1
4
5
9G53-088
1. RIGHT CHIN WINDSCREEN 4. LEFT COCKPIT WINDSCREEN
2. RIGHT COCKPIT WINDSCREEN 5. LEFT CHIN WINDSCREEN
3. COCKPIT INSTALLATION
Figure 201. Cockpit Windscreens
Page 202
Original 53-10-00
40.00 IN (101.6 cm) C
15.00 IN (38.1 mm)

9G53-120
Figure 202. Windscreen Repairs Zones
Table 201. Windscreen Allowable Repairs

Part Number Name Zone Maximum Depth Maximum Length Minimum Spacing
900F3305405 Windscreen A 0.01 in (0.025 mm) 1.0 in (2.54 cm) 2.0 in (5.08 cm)
B 0.02 in (0.51 mm) 3.0 in (7.62 cm) 1.0 in (2.54 cm)
C 0.03 in (0.76 mm) 6.0 in (15.2 cm) 0.5 in (12.7 mm)
900F2305607 Chin Windscreen All 0.03 in (0.76 mm) 6.0 in (15.2 cm) 0.5 in (12.7 mm)
C. Windscreen Inspection (2). Inspect windscreen edge sealant for

cuts, tears, cracks, or deterioration.
(Ref. Figure 202 and Table 201) None allowed.
(1). Inspect all windscreens for cracks, (3). Inspect for loose or missing fasteners.
scratches and obstructions to visibility. None allowed.
Page 203
53-10-00 Original
2. Windscreen Wipers (5). Install nut and washer attaching arm

to wper blade onto wiper blade. Torque
A. Wiper Blade Removal nut (Ref. CSP-SPM).
(Ref. Figure 205) (6). Torque hub bolt (Ref. CSP-SPM).
(1). Remove nuts (7) and washers (8) (7). Perform rigging check (Ref. R. (EARLY
attaching wiper blade to wiper arm and CONFIG) or S. (CURRENT CONFIG)
link assembly. Remove blade. Windscreen Wipers Rigging/Operational
Check).
B. Wiper Blade Installation
E. Wiper Link Removal (EARLY CONFIG)
(Ref. Figure 205)
(1). Position wiper blade with attached
studs through wiper arm and link (1). Remove nut (7) and washer (8)
assembly and install washers and Figure 205 and remove wiper link from
attachment nuts. Torque nuts (Ref. wiper blade (1 or 2).
CSP-SPM). (2). Remove bolt (6) and washer (7)
Figure 203 and remove link from
C. Wiper Arm Removal
bracket (38 or 39) and clamp assembly
(Ref. Figure 203 and Figure 205) (14).
(1). Remove nut (7) and washer (8) F. Wiper Link Installation (EARLY CONFIG)
Figure 205 from wiper blade. (Ref. Figure 203 and Figure 205)
(2). Remove nut (33) and washer (34) (1). Install link onto bracket and clamp
Figure 203, attaching wiper arm to assembly and install bolt and washer.
motor shaft. Torque bolt to allow free rotation of
link, minimizing freeplay.
(3). Loosen hub bolt (37).
(2). Install link onto wiper blade and install
(4). Straighten arm and remove arm from nut and washer. Torque nut (Ref.
motor shaft and wiper blade. CSP-SPM).
D. Wiper Arm Installation G. Wiper Link Removal (CURRENT CONFIG)
(Ref. Figure 203 and Figure 205) (Ref. Figure 203 and Figure 205)
Ensure wiper motor is in the (1). Remove bolt (9), washer (10) and nut
CAUTION PARK position prior to instal (11) Figure 205 and remove wiper link
ling arm. from upper link (14).
(1). Apply electrical power to the helicopter (2). Remove cotter pin (10), nut (9), washers
and verify that the motor is in the (8 and 7) and bolt (6) Figure 203 and
PARK position. Remove power (Ref. remove link from bracket (38 or 39).
Section 96-00-00). H. Wiper Link Installation (CURRENT
(2). Position wiper arm over wiper motor CONFIG)
shaft and wiper blade. Ensure wiper (Ref. Figure 203 and Figure 205)
arm is positioned correctly (Ref.
Figure 205). (1). Install link onto bracket and install
bolt, washer and nut. Torque bolt to
(3). Install wiper arm onto motor shaft and allow free rotation of link, minimizing
wiper blade. freeplay. Intall new cotter pin.
(4). Install nut and washer onto motor (2). Install link onto upper link and install
shaft. Torque nut maximum of 60 in lb bolt, washer and nut. Torque nut (Ref.
(6.78 Nm). CSP-SPM).
Page 204
I. Wiper Arm Clamp Removal (EARLY (1). Position wiper motor and install bolts
CONFIG) and washers. Torque bolts (Ref.
CSP-SPM).
(Ref. Figure 203)
Verify proper P535/P536 con
(1). Remove wiper arm assembly. CAUTION nection.
(2). Remove link assembly. (2). Prepare surface for electrical bond (Ref.
(3). Remove screws (40), washers (41 and CSP-SPM).
42), nuts (43) and remove bracket (38 (3). Attach bonding jumper and electrical
or 39). connection.
(4). Remove bolt (20), washers (21), and nut (4). Perform electrical bond check Class L
(22) from clamp (14) and remove clamp. (Ref. CSP-SPM).
J. Wiper Arm Clamp Installation (EARLY Sealing Compound (C205)
CONFIG)
(Ref. Figure 203)
(1). Install clamp onto wiper motor shaft
and install bolt, washer, and nut. (5). Seal bonding jumper attaching hard
ware with sealing compound (C205)
(2). Install bracket washers, screws, and (Ref. CSP-SPM).
nuts. Torque nuts 8-10 in lbs
(0.90-1.13 Nm). (6). Install wiper arm clamp (EARLY
CONFIG).
(3). Install link assembly.
M. Wiper Motor Mounting Bracket Removal
(4). Install wiper arm assembly.
(Ref. Figure 203)
Ensure clamp is located axially
CAUTION flush with shoulder below (1). Remove wiper motor.
splined motor output shaft.
(2). Remove sufficient sealant to remove
(5). Torque nut on clamp (Ref. CSP-SPM). screws (16).
K. Wiper Motor Removal (3). Remove screws (16), washers (17),
washers (18), and nuts (19).
(Ref. Figure 203)
(4). Remove bracket (2 or 5).
(1). Remove wiper arm clamp (EARLY
CONFIG). N. Wiper Motor Mounting Bracket
Installation
(2). Disconnect electrical connector and
bonding jumper. (Ref. Figure 203)
(3). Remove bolts (23) and washers (21) and

remove motor. Consumable Materials
(Ref. CSPSPM)
L. Wiper Motor Installation Item Nomenclature
(Ref. Figure 203)
Consumable Materials (1). Replace unserviceable fay material

(Ref. CSPSPM) (25).
Item Nomenclature (2). Install bracket ensuring alignment of
C205 Sealing Compound wiper motor shaft hole in bracket and
windscreen.
Page 205
(3). Install screws, washers , and nuts. P. Relay Panel Installation

Torque nuts (Ref. CSP-SPM).
Power Off

helicopter (Ref. Section 96-00-00).
(4). Seal mounting hardware with sealing
compound (C205). (2). Place relay panel (3) in position and
install screws (1) and washers (2).
(5). Install wiper motor. Torque screws.
O. Relay Panel Removal (3). Attach connector P539 to connector J1.
(Ref. Figure 204) (4). Install access panels PL120 and PR120
Power Off (5). Restore power to helicopter (Ref.
Section 96-00-00).
Q. Windscreen Wiper Inspection
helicopter (Ref. Section 96-00-00). (1). Inspect all hardware for condition and
security. Tighten/replace any loose/un
(2). Remove access panels PL120 and serviceable hardware.
PR120 (Ref. Section 06-00-00).
(2). Inspect wiper blade for deterioration.
(3). Detach connector P539 from connector None allowed.
J1. (3). Inspect electrical components for
condition and security. Repair/replace
(4). Remove screws (1) and washers (2) any unserviceable components.
attaching relay panel (3). Remove relay
panel. (4). Check rigging of wiper installation.
Page 206
31
25 (2 PL)
32
25 (4 PL)
23 (4 PL)
27
24 (4 PL)
9 REF
1
3 (2 PL)
ROTATED 180 33 (2 PL) 2
LH SHOWN RH OPP 37 34 (2 PL)
4
35 (2 PL)
20 (2 PL) 36 (2 PL)
21 2X (2 PL)
22 (2 PL) 5
39 6 (2 PL)
7 2X (2 PL)
8 2X (2 PL)
9 (2 PL)
10 (2 PL)
11 (2 PL)
12
16 (4 PL)
17 (4 PL)
18 (4 PL) 15
19 (4 PL)
40 (4PL) 38
41 (4PL)
42 (4PL) 14 (2 PL) 13 (2 PL)
43 (4PL) 29 (8 PL)
30 (16 PL)
9G53-126-1
Figure 203. Windscreen Wiper Installation (Sheet 1 of 2)
Page 207
28
46
(EARLY CONFIGURATION)
46
WIPERS
HI
LO
OFF
46
44
(CURRENT CONFIGURATION)
(CURRENT CONFIGURATION)
(OPTIONAL LOCATIONS)
WINDSCREEN
WIPER CONTROL 9G53-126-2
Figure 203. Windscreen Wiper Installation (Sheet 2 of 2)
Page 208

1. LINK ASSEMBLY, RH 24. WASHER, FLAT
2. BRACKET ASSEMBLY, RH 25. FAY MATERIAL
3. ARM WIPER 26. SPACER, SLEEVE
4. LINK ASSEMBLY, LH 27. JUMPER, BONDING
5. BRACKET ASSEMBLY, LH 28. SWITCH INSTALLATION (EARLY CONFIG)
6. BOLT, HEX HEAD 29. NUTPLATE, SELF LOCKING
7. WASHER, NYLON 30. RIVET, FLUSH
8. WASHER, FLAT (CURRENT CONFIG) 31. WIPER BLADE, RH
9. NUT, SELF LOCKING, CAST (CURRENT CONFIG) 32. WIPER BLADE, LH
10. COTTER PIN (CURRENT CONFIG) 33. NUT, WIPER ARM ATTACH
11. INSERT, SELF LOCKING (EARLY CONFIG) 34. WASHER, HUB
12. MOTOR ASSEMBLY, LH 35. BOLT, TENSION ADJUST
13. GROMMET 36. WASHER, FLAT
14. CLAMP ASSEMBLY (EARLY CONFIG) 37. BOLT, HUB
15. MOTOR ASSEMBLY, RH 38. BRACKET, LH
16. SCREW, PAN HEAD 39. BRACKET, RH
17. WASHER, FLAT 40. SCREW, PAN HEAD
18. WASHER, FLAT 41. WASHER, FLAT
19. NUT, HEX, SELF LOCKING 42. WASHER, FLAT
20. BOLT, HEX HEAD (EARLY CONFIG) 43. NUT, HEX, SELF LOCKING
21. WASHER, FLAT (EARLY CONFIG) 44. HOUSING ASSY, SWITCH (CURRENT CONFIG)
22. NUT, HEX, SELF LOCKING (EARLY CONFIG) 45. PANEL ASSY, AUX TOGGLE SW (CURRENT CONFIG)
23. SCREW, PAN HEAD 46. SWITCH, TOGGLE (CURRENT CONFIG)
Page 209
1
2
( 3 PLCS )
LOOKING INBOARD
9g53-130
1. SCREW 3. PANEL, WINDSCREEN WIPER RELAY

2. WASHER
Figure 204. Windscreen Wiper Relay Panel
Page 210
R. Windscreen Wipers Rigging/Operational PARK position (Ref. Section

Check (EARLY CONFIG) 96-00-00).
(Ref. Figure 205) (2). Remove power from aircraft (Ref.

Section 96-00-00).
Do Not operate wipers on a dry
CAUTION windscreen. (3). Verify that wiper blade attach end of
wiper arms are 2.0-4.5 in (5.1-11.4
(1). Apply electrical power to the helicopter cm) from aircraft BL 0.00.
and verify that the motor is in the
PARK position (Ref. Section (4). If adjustment is required, loosen hub
96-00-00). bolt (37) and nut (33) (Ref. Figure 203).
Reposition arm (3. Torque nut (33) to a
(2). Remove power from aircraft (Ref. maximum of 60 in lb (6.78 Nm).
Section 96-00-00).
CAUTION windscreen.
(3). Verify that wiper blade attach end of
wiper arms are 2.0-4.5 in (5.1-11.4 (5). Apply electrical power to the helicopter
cm) from aircraft BL 0.00. and operate windscreen wipers on low
(4). If adjustment is required, loosen bolt
(20) and nut (22) (Ref. Figure 203) and (6). If clean sweep of windscreen is not
hub bolt (37) and nut (33). Reposition attained, perform Wiper Arm Tension
arm (3) and clamp (14). Torque nut (33) Adjustment (Ref. procedure T.).
to a maximum of 60 in lb (6.78 Nm).
Torque remaining hardware (Ref. T. Wiper Arm Tension Adjustment
CSP-SPM).
(Ref. Figure 203)
CAUTION windscreen.
(Ref. CSPSPM)
(5). Apply electrical power to the helicopter
Item Nomenclature
and operate windscreen wipers on low
(Ref. Section 96-00-00). C701 Lockwire
(6). If clean sweep of windscreen is not

attained, perform Wiper Arm Tension (1). Remove lockwire from adjustment bolt
Adjustment (Ref. procedure T.). (35).
(7). Turn windscreen wipers to off, then to CAUTION windscreen.
park. Wipers should return to the park
position. (2). Apply electrical power to the helicopter
and operate windscreen wipers (Ref.
(8). Remove power from aircraft (Ref.
Section 96-00-00).
Section 96-00-00).
(3). Torque bolt (35) minimum required to
S. Windscreen Wipers Rigging/Operational obtain a clean sweep of the windscreen.
Check (CURRENT CONFIG)
(4). Turn windscreen wipers to off, then to
(Ref. Figure 205) park. Wipers should return to the park
position.
CAUTION windscreen. (5). Remove power from aircraft (Ref.
Section 96-00-00).
(1). Apply electrical power to the helicopter
and verify that the motor is in the (6). Safety bolt with lockwire (C701).
Page 211
2 (REF)
7 (4 PL)
8 (4 PL)
1 (REF)
EARLY CONFIGURATION
4 (REF)
2.0-4.5 IN
( 5.1-11.4 cm )
2.0-4.5 IN
3 (REF) ( 5.1-11.4 cm )
7 (2 PL)
8 (2 PL)
2
6 (REF) 5 (REF)
12 (2 PL)
13 (2 PL)
9 (2 PL)
10 (4 PL)
11 (2 PL)
14
CURRENT CONFIGURATION 3
5
9G53-127
1. WIPER BLADE, LH 8. WASHER, PLASTIC (EARLY CONFIG)

2. WIPER BLADE, RH 9. BOLT (CURRENT CONFIG)
3. LINK ASSEMBLY, LH 10. WASHER, FLAT (CURRENT CONFIG)
4. LINK ASSEMBLY, RH 11. NUT, SELFLOCKING (CURRENT CONFIG)
5. ARM, WIPER 12. WASHER (CURRENT CONFIG)
6. ARM, WIPER 13. SPACER (CURRENT CONFIG)
7. NUT, SELF LOCKING (EARLY CONFIG) 14. LINK, UPPER (CURRENT CONFIG)
Figure 205. Windscreen Wiper Rigging/Operational Check
Page 212
3. Landing Light Window Panel (N82) C. Landing Light Window Panel Installation
(Ref. Figure 206)
A. Landing Light Window Panel Inspection
(1). Position landing light window panel in
(Ref. Table 202) frame and align screw holes.
(2). Secure window to airframe with screws,
(1). Inspect window panel for pits, cracks, packing washers and flat washers.
scratches and general condition. Repair
or replace as required. 4. Nose Access Door (N80)
A. Nose Access Door Inspection
(2). Inspect for loose or missing fasteners.
Repair or replace as required. (1). Inspect door for general condition and
security. No damage allowed.
B. Landing Light Window Panel Removal
(2). Inspect door lock (if applicable) and
quarter-turn fasteners for security and
(Ref. Figure 206) verify proper operation. No damage
allowed.
(1). Remove screws, packing washers and
flat washers which secure landing light (3). Inspect hinges for proper operation,
window panel into airframe. loose or missing fasteners. Repair or
replace as required.
(2). Remove window from airframe, using (4). Inspect door frame seal for security and
care to prevent damage to seal bond serviceable condition. No damage
surfaces. allowed.
Table 202. Landing Light Window Allowable Repairs
Part Number Name Zone Maximum Depth Maximum Length Minimum Spacing
900F2305048 Window, Landing Light All 0.03 in (0.76 mm) 6.0 in (15.2 cm) 0.5 in (12.7 mm)
Page 213
1
2 9G53-086
1. NOSE ACCESS DOOR (N80)
2. LANDING LIGHT WINDOW (N82)
Figure 206. Landing Light Window Panel / Nose Access Door
B. Nose Access Door Removal (1). Prepare surface for electrical bond (Ref.
CSP-SPM).
(Ref. Figure 206)
(1). Unlock nose access door (if applicable). (2). Secure door and bonding leads to
hinges with screws, washers and nuts.
(2). Disengage quarter-turn fasteners at
Torque nuts.
bottom of door. Open door.
(3). Remove sealant from hinge attach Sealing Compound (C203)
points at top of inside surface of door.
(4). Remove screws, washers and nuts
which secure door and bonding leads to
hinges.
C. Nose Access Door Installation
(Ref. Figure 206) bonding lead terminals and attaching
hardware.
(Ref. CSPSPM) (4). Close door and engage quarter-turn
Item Nomenclature fasteners.
(5). Lock nose access door (as required).
Page 214
Section
532000
Lower and Center
Fuselage
LOWER AND CENTER FUSELAGE

1. Fuselage Lower and Center General are the console installation, the general tub
assembly, the side skin installation, the
(Ref. Figure 1)
cockpit, cabin, and baggage floor installations,
The major subassemblies and installations the door track installation, and the upper and
that are contained in this area of the fuselage lower work platform installations.
UPPER WORK
PLATFORM
INSTALLATION
CONSOLE LOWER WORK

INSTALLATION PLATFORM
INSTALLATION
BAGGAGE FLOOR
INSTALLATION
DOOR TRACKS
INSTALLATION
CABIN FLOOR
INSTALLATION
COCKPIT FLOOR SIDE SKIN GENERAL TUB

INSTALLATION INSTALLATION ASSEMBLY
9G53-027
Figure 1. Fuselage Lower and Center Area
Page 1
53-20-00 Original
2. General Tub Assembly Avionics Access Panel Assemblies The left

and right avionics access panel assemblies
(Ref. Figure 2) include an access panel, a mounting frame,
access panel seal and miscellaneous mounting
The major components that are included in the brackets and hardware.
general tub assembly are the tub shell
assembly, cockpit subfloor support structure Aircraft Serial Numbers 900-00010
assembly, FS 155.50 tub bulkhead, FS 155.50 through 900-00017 - The access panel is
frame assembly, FS 230.50 tub bulkhead fabricated as a composite sandwich panel that
assembly, FS 230.50 lower frames assemblies, utilizes skins and reinforcement plies of epoxy
cabin door frame assemblies, forward and aft resin impregnated carbon fiber fabric and
skid landing gear attachments, and the boat epoxy resin impregnated fiberglass fabric
tail assembly. cocured with a syntactic epoxy foam core. In
addition, a ply of Astrostrik
is cocured to the
Additional subassemblies and component parts exterior surface of the panel.
that are contained in the general tub assembly
Aircraft Serial Numbers 900-00018
are the forward and aft fuel cell liner assem
through 900-99999 - The access panel is
blies, access panel cover assemblies, work
fabricated from aluminum alloy sheet.
platform structures, left and right step rib
assemblies, seat and (cargo) tie-down fittings, The mounting frames are fabricated from
and various stiffening, support, and secondary aluminum alloy sheet. Each respective
components. mounting frame is secondarily fastened to the
interior surface of a cutout in the tub shell of
Hardware within this assembly includes the tub assembly. Fastening is by rivets.
various metallic and composite base nutplates,
studs, and receptacles. Metallic base compo Center, Sump, Fuel Drain Access Panel
nents are either mechanically fastened or Assemblies Each of these access panel
bonded. Composite base components are assemblies include an access panel, a mount
bonded only. Floating barrel nuts and retain ing frame, access panel seal, and miscella
ers are utilized at the forward and aft skid neous mounting hardware.
attachments for retention of the landing cross
tubes. The access panels within these assemblies are
A. Access Panel and Covers Assemblies The mounting frames within each of these
assemblies are also fabricated from aluminum
The access panels and covers include the left alloy sheet. The frames are secondarily
and right avionics access panel assemblies, the fastened to the interior surface of the tub shell
center access panel assembly, the sump access in the tub assembly by rivets.
panel assembly, the fuel drain access panel
assembly, and the aft crosstube cover. All Aft Crosstube Cover The aft crosstube cover
panels are secondary structural components. is fabricated from aluminum alloy sheet.
Page 2
B. Fuel Cell Liner Assemblies resin impregnated carbon fiber fabric are
inlaid.
The fuel cell liner assemblies, installed as a
Support Rib Channels The support rib
forward and aft assembly, are secondary channels are secondary structural components
structural components that distribute the that capture the upper edge of each respective
vertical load produced by the fuel in the fuel fuel cell rib when the fuel cell liner assemblies
cell to the fuel cell ribs and keel beams of the are installed.
tub assembly, and the FS 155.50 and the FS
230.50 bulkheads. Each assembly is installed Each support rib channel is fabricated using
with seals, and together forms the lower one ply of aramid/epoxy and one ply of
closure panel for the fuel cell cavity. carbon/epoxy cocured as a monolithic lami
nate. The channels are installed on the
Each liner assembly is fabricated from underside of each fuel cell liner panel using
multiple details. The primary components rivets and secondary bonding. The forward
within each assembly are the fuel cell liner fuel cell liner assembly utilizes nine support
panel, support rib channels, insulators, and rib channels and the aft fuel cell liner utilizes
beads. one support rib channel.
Insulators The insulators are fiberglass
Fuel Cell Liner The fuel cell liner panel is barriers that are bonded over the heads of the
fabricated as a composite sandwich panel that rivets (on the fuel cell side) that secure the
utilizes multiple ply epoxy resin impregnated support rib channels.
carbon fiber fabric and epoxy resin impreg
nated fiberglass fabric skins cocured with a Beads The beads are rubber strips that are
Nomex honeycomb core. In areas in which bonded to the upper surface of the fuel cell
secondary attachment of the support rib liner panels. The beads provide for the
channels occurs the honeycomb core is tapered drainage of fuel from the fuel cell cavity in the
and additional reinforcement plies of epoxy event of fuel leakage from the fuel cell.
Page 3
FUEL CELL LINER
FUEL CELL
LINER SEALS
RH FS 218.50 DOOR
FS 155.50 FRAME FRAME ASSEMBLY
RH FS 230.50 LOWER LH FS 218.50 DOOR

FRAME ASSEMBLY FRAME ASSEMBLY
LH FS 230.50 LOWER
FS 230.50 TUB FRAME ASSEMBLY
BULKHEAD
ASSEMBLY
BOAT TAIL
FUEL DRAIN ACCESS ASSEMBLY
PANEL ASSEMBLY
RH AVIONICS ACCESS
PANEL ASSEMBLY
TUB
SHELL ASSEMBLY
LH FS 166.50 DOOR
FRAME ASSEMBLY
(RH OPPOSITE)
AFT CROSSTUBE COVER

COCKPIT SUBFLOOR
SUPPORT STRUCTURE ASSEMBLY
CENTER ACCESS
PANEL ASSEMBLY SUMP ACCESS
LH AVIONICS ACCESS PANEL ASSEMBLY
NOTE: FWD SKID ATTACHMENT FITTING AND AFT PANEL ASSEMBLY
SKID ATTACHMENT ASSEMBLY ARE NOT SHOWN.
9G53-028A
Figure 2. General Tub Assembly
Page 4
C. Tub Shell Assembly that support the loads in the vertical direction
produced by the fuel in the fuel cell. Six fuel
(Ref. Figure 3) cell support ribs are positioned laterally
The tub shell assembly is fabricated from between the keel beams, and are located at FS
multiple composite detail parts joined together 166.50, FS 176.60, FS 190.25, FS 199.20, FS
by bonding or rivets.The primary components 209.90, and FS 220.20. The ribs are mechani
included in this assembly are the tub shell, the cally fastened to the keel beams by means of
left and right keel beams, and the fuel cell auxiliary cleats or angles.
support ribs. Secondary components include Early Configuration - The ribs are secondarily
the cockpit and cabin sills, tub shell longerons, bonded to the tub shell.
fuel cell liner attachment angles, lower door Current Configuration - Fuel cell support ribs
track pockets, and miscellaneous support are riveted to the tub shell.
angles.
All fuel cell ribs are fabricated as composite
Tub Shell The tub shell is a primary sandwich panels, that utilize multiple ply
structural component and is the load bearing graphite/epoxy skins cocured with Nomex
skin of the lower section of the fuselage. honeycomb cores. The honeycomb core
terminates at the integral attachment flanges
The sides of the tub shell are fabricated as a which are monolithic laminates.
composite sandwich panel that is typically two
ply outer and one ply inner graphite/epoxy Auxiliary Components The auxiliary
skins cocured with a Nomex honeycomb core. components, such as the cockpit and cabin
In areas in which secondary attachment of sills, tub shell longerons, fuel cell liner
additional components will occur, the honey attachment angles, and the lower door track
comb core is tapered and additional reinforce pockets are secondary structural components.
ment plies of graphite/epoxy are inlaid. The
center section between LBL 24 and RBL 24 is These auxiliary components are all composite
typically three ply graphite/epoxy solid monolithic laminates utilizing multiple plies of
laminate. In areas in which secondary graphite/epoxy.
attachment of additional components occur,
additional reinforcement plies of graphite/ The primary function of the cockpit and cabin
epoxy are inlaid. In areas in which secondary sills are to provide for attachment of the
attachment of metallic components occurs, a cockpit and cabin compartment floor panels.
barrier ply of fiberglass/epoxy is cocured to the The function of the tub shell longerons is to
surface of the respective skin. On the exterior provide stiffening of the tub shell. The function
surface of the tub shell a barrier ply of of the fuel liner attachment angles is to
fiberglass/epoxy and a ply of Astrostrik
is provide provisions for attachment of the fuel
cocured to the panel. cell liner. The primary function of the door
track pockets is to provide attachment of the
Fuel Cell Support Ribs The fuel cell support forward ends of the lower door tracks for the
ribs are the primary structural components cabin doors.
Page 5
RH KEEL BEAM
ASSEMBLY
FUEL CELL
SUPPORT RIBS LH KEEL BEAM
ASSEMBLY
FUEL CELL LINER
ATTACHMENT ANGLE
(LH AND RH TYPICAL)
COCKPIT SILL
(LH AND RH TYPICAL)
CABIN SILL
(LH AND RH TYPICAL)
LOWER DOOR TRACK POCKET

TUB SHELL
LONGERONS TUB SHELL
9G53-029A
Figure 3. Tub Shell Assembly

Keel Beams The left and right keel beams The keel beams are composite sandwich
are primary structural components and are panels. The panels utilizes multiple ply
the longitudinal and vertical load bearing graphite/epoxy and aramid/epoxy skins
structural components of the lower section of cocured with Nomex honeycomb cores. In
the fuselage. In addition, the keel beams form areas in which secondary attachment of
the side walls of the fuel cell cavity and additional components occurs, the honeycomb
support the loads produced by the fuel in the core is tapered and additional reinforcement
fuel cell. The keel beams are symmetrically plies of graphite/epoxy are inlaid. In areas in
located within the tub shell assembly, at LBL which secondary attachment of metallic
and RBL 24.00. components occurs, a barrier ply of fiberglass/
epoxy is cocured to the surface of the respec
tive skin. The keel beam panels are fabricated
Early Configuration keel beams are second
with integral upper and lower flanges. The
arily bonded to the interior skin of the tub
lower flanges are utilized for attachment of the
shell and riveted to the boat tail tub.
keel beams to the tub shell and boat tail
assembly. The upper flanges provide the
Current Configuration keel beams are provisions for attachment of the cabin and
riveted to the tub shell and the boat tail tub. baggage compartment floor panels.
Page 6
D. Cockpit Subfloor Support Structure Each assembly combines a vertical web, with
Assembly an integral upper flange, a lower flange cap,
and several vertical stiffening channels and
(Ref. Figure 4 and Figure 5) angles. All components within each assembly,
The cockpit subfloor support structure with the exception of the secondary attach
assembly provides the support for the cockpit ment angle along the aft edge and hardware,
floor panels, the structural interface and are fabricated from aluminum alloy sheet. The
mounting provisions for the cockpit console, secondary attachment angles are machined
the crew seats, and the cockpit mounted flight from aluminum alloy extrusions. All compo
control components. In addition, this assembly, nents within these assemblies are joined using
forms the left, center, and right avionics bays. rivets.
The major components that are included in

FS 106.00 Tub Bulkhead Assembly The FS
this assembly are the left and right plough
106.00 tub bulkhead assembly is primary
beam assemblies, the FS 106.00 tub bulkhead
structure that supports load in the lateral and
assembly, and the FS 130.00 tub bulkhead
vertical direction.
assembly.
Secondary components include console The assembly consists of left, center, and right
supports, crew seat fittings, the channel bulkhead webs, (directional) pedal bracket
adaptor fitting, left and right cyclic floor support fittings, floor panel gussets, tension
fittings, miscellaneous stiffeners and channels, clips, and plough beam attachment angles.
reinforcing intercostals and gussets, attach The left and right bulkhead webs are posi
ment angles, cleats, and clips. tioned between the interior surface of the tub
All subassembly components within this shell and each respective plough beam
assembly are joined using rivets or pins and assembly. The center bulkhead web is posi
collars. tioned aligned with the left and right webs
between the plough beams. These components
Plough Beam Assemblies The left and right are mechanically joined to the tub shell and
plough beam assemblies are located at LBL plough beams by rivets. All components, with
and RBL 8.50. These assemblies are primary the exception of the pedal bracket support
structural components and support cockpit fittings, are fabricated from aluminum alloy
loads in the longitudinal and vertical direc sheet. The pedal bracket support fittings are
tions. machined from aluminum alloy stock.
Page 7
53-20-00 Original
CREW SEAT FITTING

(6 PER CREW SEAT)
RH PLOUGH
BEAM ASSEMBLY
LH PLOUGH FS 130.00 TUB

BEAM ASSEMBLY FS 106.00 TUB BULKHEAD ASSEMBLY
BULKHEAD ASSEMBLY 9G53-030
Figure 4. Cockpit Subfloor Support Structure Assembly

FS 130.00 Tub Bulkhead Assembly The FS These fittings are machined from aluminum
130.00 tub bulkhead assembly is primary alloy stock. Attachment of the inboard crew
structure that supports loads in the lateral seat fittings is by means of secondary channels
and vertical direction. The assembly attaches attached to the web of each respective plough
the cockpit floor panels, the left and right beam. Attachment of the outboard fittings is
cyclic support structure, and the forward ends by means of similar secondary channels
of the keel beams. attached to each respective keel beam. The
fittings are attached by rivets, or pins and
The assembly consists of left, center, and right collars.
bulkhead webs, keel beam, plough beam, web
Channel Adaptor and Cyclic Floor Fittings
attachment angles, floor panel gussets,
The channel adaptor and the cyclic floor
doublers, and a stiffener for the center web. All
fittings provide the provisions for attachment
components within this assembly, excluding
of cockpit mounted flight control components.
the hardware, are fabricated from aluminum
The channel adapter is a primary structural
alloy sheet. All components are joined with
component due to its support of the collective
rivets.
and cyclic control bellcrank assemblies. The
cyclic floor fittings are secondary components
Crew Seat Fittings The crew seat fittings due to redundant support locations.
provide the structural interface between the
crew seat assemblies and the cockpit subfloor The channel adaptor and cyclic floor fittings
support structure assembly. There are six crew are machined from aluminum alloy stock.
seat attachment fittings, three inboard and Each fitting is fastened to adjacent structure
three outboard, that support each crew seat. by rivets.
Page 8
Original 53-20-00
E. FS 155.50 Tub Bulkhead Assembly stock. Each fitting is joined to adjacent

structure by pins and collars.
(Ref. Figure 5)
G. FS 155.50 Frame Assembly
The FS 155.50 tub bulkhead assembly is a
primary structural component. This bulkhead (Ref. Figure 5)
supports loads in the lateral and vertical
directions. In addition, this bulkhead assembly The FS 155.50 frame assembly is a primary
forms the forward wall of the fuel cell cavity structure. This frame assembly provides
and supports the loads produced by the fuel in support for loads in the vertical and lateral
the fuel cell. This assembly is installed into the directions. This frame assembly attaches the
tub assembly between the keel beams. upper end of the cockpit assembly, contributes
to the support of the forward end of the roof
This assembly incorporates a vertical web, assembly, and provides for attachment at the
reinforcing doublers and plates, secondary forward end of the fairings located on the
angles for attachment of the cockpit and cabin fuselage upper deck area. This frame assembly
floors, a secondary angle for attachment of the also separates the crew station from the
fuel cell liner, and secondary keel beam passenger cabin. At the lower end, it is
attachment angles. All components in this mechanically fastened to the tub shell and keel
assembly, excluding the hardware, are beams of the tub assembly. Along the vertical
fabricated from aluminum alloy sheet. sides this assembly is mechanically fastened to
Attachment of all components within this each side skin assembly. At the top end this
assembly, as well as secondary attachment of assembly is mechanically fastened to adjacent
this assembly into the tub assembly, is by structure of the roof assembly and the cockpit
rivets. assembly.
F. Forward Skid Attachment Fittings This assembly incorporates left and right
vertical frame subassemblies joined by a splice
(Ref. Figure 5) plate, reinforcing strap, a secondary attach
The left and right forward skid attachment ment along the top edge, and a secondary
fittings are primary structural components. attachment angle along the edge of the
These fittings are the provisions for mounting through opening. Each vertical frame subas
of the forward crosstube of the landing gear sembly, is also a built-up assembly consisting
subsystem. Each fitting is located at LBL and of a web with integral attachment flanges,
RBL 8.50, and mount in the corners formed by doublers, stiffeners, and angles. All compo
the intersections of the plough beams of the nents within this assembly and subassemblies,
cockpit subfloor support structure assembly excluding the hardware, are fabricated from
and the FS 155.50 tub bulkhead assembly. aluminum alloy sheet. All fastening within
this assembly and the subassemblies, as well
The left and right forward skid attachment as the mechanical fastening of this assembly
fittings are machined from aluminum alloy to adjacent structural components is by rivets.
Page 9
FS 155.50 FRAME
ASSEMBLY
TUB ASSEMBLY
(REFERENCE)
FS 155.50 TUB
BULKHEAD ASSEMBLY
RH FWD SKID
ATTACHMENT
FITTING
LH FWD SKID
ATTACHMENT FITTING 9G53-031A
Figure 5. FS 155.50 Tub Bulkhead and Frame Assemblies, Forward Skid Attachment Fittings
Page 10
H. FS 230.50 Tub Bulkhead Assembly Each assembly incorporates a vertical web,

web doubler plate, an inboard reinforcing
(Ref. Figure 2) channel, horizontal stiffening angles, second
ary attachment angles, a splice plate, and a
The FS 230.50 bulkhead assembly is a butt joint strap. All components within each
built-up assembly that is a primary structure. assembly are, with the exception of the
This bulkhead assembly provides support for secondary keel beam attachment angles and
loads in the lateral and vertical directions. the hardware, fabricated from aluminum alloy
This bulkhead assembly also forms the aft sheet. The secondary keel beam attachment
wall of the fuel cell cavity and supports the angles are machined from aluminum alloy
loads produced by the fuel in the fuel cell. In extrusion. Attachment of all components
addition, this bulkhead assembly provides for within this assembly, as well as secondary
attachment of the aft skid attachment attachment of this assembly to adjacent
assembly. This assembly is installed into the structural components, is by rivets.
tub assembly between the keel beams, against
the interior surface of the aft flange of the tub J. Aft Skid Attachment Assembly
shell.
(Ref. Figure 6)
NOTE: The bracket for attachment of the fuel
system crossfeed valve, is not installed on The aft skid attachment assembly is a primary
902 CONFIG aircraft. structural component that includes the
attachment for mounting of the aft crosstube.
This assembly incorporates a two piece vertical This assembly, which is secondarily fastened to
web, a reinforcing plate, two vertical stiffeners, the tub shell and keel beams of the tub
secondary angles for attachment of the cabin assembly and to the FS 230.50 tub bulkhead
and baggage compartment floors, a secondary assembly, transfers vertical, lateral, and
angle for attachment of the fuel cell liner, and longitudinal loads from the aft crosstube into
a bracket for attachment of the fuel system the fuselage structure. Secondary fastening of
crossfeed valve. All components in this this assembly is by rivets. This assembly also
assembly, excluding the hardware, are provides for attachment of the lower edges of
fabricated from aluminum alloy sheet. the boat tail assembly.
Attachment of all components within this Components that are included in this assembly
assembly, as well as secondary attachment of are the crosstube box panels, left and right aft
this assembly into the tub assembly, is by skid attachment fittings, keel beam attach
rivets. ment fittings, doublers, horizontal and vertical
I. FS 230.50 Lower Frame Assemblies stiffening angles and channels, and reinforcing
angles. All components, with the exception of
(Ref. Figure 2) the aft skid attachment, the hardware, and
keel beam fittings, are fabricated from
The left and right FS 230.50 lower frame aluminum alloy sheet. The aft skid attach
assemblies are primary structural components. ment fittings are machined from aluminum
These assemblies join the aft outboard ends of alloy stock. The keel beam attachment fittings
the tub assembly, the forward vertical ends of are machined from aluminum alloy extrusions.
the rear fuselage shell assemblies, and the mid Attachment of all components within this
section of the roof assembly. These assemblies assembly, as well as secondary attachment of
provide support in the vertical and lateral this assembly to adjacent structural compo
directions. nents, is by rivets or pins and collars.
Page 11
K. Cabin Door Frames Assemblies The components included in this assembly are
the boat tail tub, the boat tail sills, attachment
(Ref. Figure 2) cleats, spoiler attachment inserts, and bonded
nutplates.
The cabin door frame assemblies are second
ary structural components. These components Boat Tail Tub The boat tail tub is a primary
support loads in the vertical and lateral structural component and is the load bearing
directions. These assemblies attach to the tub skin in the aft lower section of the fuselage.
shell and keel beams of the tub assembly, the
edge of the panel that forms the cabin door The boat tail tub is a composite sandwich
opening, and adjacent structure of the roof panel that utilizes multiple ply graphite/epoxy
assembly. Secondary attachment of these skins cocured with a Nomex honeycomb core.
assemblies is by rivets. Each assembly also In areas in which secondary attachment of
provides for attachment of the cabin floor additional components will occur, the honey
panels. comb core is tapered and additional reinforce
ment plies of graphite/epoxy are inlaid. In
FS 166.50 Door Frame Assemblies The left areas in which secondary attachment of
and right FS 166.50 door frame assemblies are metallic components will occur, a barrier ply of
located along the forward lower edge of the fiberglass/epoxy is cocured to the surface of the
cabin door openings. respective skin. On the exterior surface of the
boat tail tub a ply of Astrostrik
is cocured to
the panel.
Each assembly consists of an upper frame, a
lower riblet, and secondary attachment angles.
All components within these assemblies, Boat Tail Sills The boat tail sills are second
excluding the hardware, are fabricated from ary structural components and are the
aluminum alloy sheet. Secondary fastening of provisions for attachment of the lower edges of
the detail components is by rivets. the rear fuselage shell assemblies. The sills
also provide the provisions for attachment of
FS 218.50 Door Frame Assemblies The left the baggage floor panels.
and right FS 218.50 door frame assemblies are
located along the aft edge of the cabin door The sills are composite on aircraft serial
openings. numbers 900-00010 through 900-00028
and are fabricated using multiple plies of
Each assembly consists of a frame, a floor graphite/epoxy cocured as a monolithic
support channel, a reinforcing angle, and an laminates. On aircraft serial numbers
attachment cleat. All components within these 900-00029 through 900-99999 the sills are
assemblies, excluding the hardware, are fabricated of aluminum alloy. The sills are
fabricated from aluminum alloy sheet. fastened to the boat tail tub by rivets.
Secondary fastening of the detail components
is by rivets. Attachment cleats The attachment cleats
are secondary structural components and
L. Boat Tail Assembly function as auxiliary attachment provisions for
the boat tail assembly.
(Ref. Figure 2)
The cleats are fabricated from aluminum alloy
The boat tail assembly, combined with the tub sheet. The cleats are fastened to the upper
assembly, forms the bottom of the fuselage flange of the boat tail sills by rivets.
structure. This assembly attaches mechanical
ly using rivets to the aft skid attachment Spoiler Attachment Inserts The spoiler
assembly, to the left and right FS 230.50 lower attachment inserts are nylon inserts that are
frame assemblies, and to the lower edge of the secondarily bonded into cored area of the boat
left and right rear fuselage shell assemblies. tail tub panel.
Page 12
RH AFT SKID
ATTACHMENT FITTING
LH AFT SKID
ATTACHMENT FITTING
KEEL BEAM
ATTACHMENT
FITTINGS
CROSSTUBE
BOX PANELS
VIEW ROTATED
CROSSTUBE BOX
ATTACHMENT ANGLE 9G53-032
Figure 6. Aft Skid Attachment Assembly
M. Step Ribs N. TieDown Fittings
The tie-down fittings are secondary structural

The step ribs are secondary structural
components that are the provisions for
components and provide for attachment of the
attachment of the passenger seat tracks and
left and right cabin steps. Four step ribs are
cargo tie-down rings.
installed between the tub shell and the
adjacent keel beam on each side of the general All of the tie-down fittings are machined from
tub assembly. aluminum alloy stock. Installation into the
general tub assembly is by pins and collars.
The step ribs are fabricated from aluminum Secondary support of these fittings is provided
alloy sheet. Fastening of these components to by attachment to the various floor panels by
adjacent components is by means of rivets. screws.
Page 13
53-20-00 Original
3. Side Skin Installation Side Skin Panel The left and right side skin
panels are composite sandwich panels that
utilizes skins and reinforcement plies of
(Ref. Figure 1) graphite/epoxy and fiberglass/epoxy cocured
with a syntactic epoxy foam core 0.020 inch
The side skin installation installs the left and (0.51 mm). Around the periphery of each
right side skin panel assemblies, the (aft) door panel, and in the areas of secondary attach
posts for the cockpit doors, and fillets at the ment of additional components, the core is
corner joints of the cockpit and cabin door tapered and the panel transitions to form
openings. Sub-components within this monolithic laminate attachment flanges. In
installation are attachment cleats, stiffeners, addition, a ply of Astrostrik
is cocured to the
and packers or shims. exterior surface of each panel.
Footsteps and Hand Grips The left and right
The side skin panel assemblies attach to the foot steps and hand grips are composite
FS 155.50 frame assembly, the A-Frame monolithic laminates. These laminates utilize
assembly, adjacent structure of the roof cocured skins and reinforcement plies of
assembly, and the left and right FS 166.50 graphite/epoxy and fiberglass/epoxy.
door frame assemblies . The door posts attach
Step Tread Plates and Grips The step plates
along the forward edge of the panel assemblies
and grips are installed within the cavity of the
and join to the cockpit door pillars of the
footsteps and hand grips respectively. These
cockpit assembly at the top, and the cockpit
components are fabricated from aluminum
sills of the tub assembly. Installation of all
alloy sheet.
components within this installation is by
rivets. Stiffeners and Support Angles The cabin
side skin stiffeners and support angles are
A. Side Skin Panel Assemblies secondary structural components. These
components are composite monolithic lami
nates utilizing cocured skins and reinforce
The left and right side skin panel assemblies ment plies of graphite/epoxy and fiberglass/
are primary structural components. These epoxy.
panel assemblies are load bearing skins that
support shear loads in the longitudinal and B. Door Posts
vertical directions. The door posts are secondary structural
components and are fabricated from aluminum
Each side skin panel assembly includes a skin alloy sheet.
panel, footstep and step tread plate, handgrip C. Fillets
and grip, stiffeners, and support angles. All
components, with the exception of the step The fillets are secondary structural compo
tread plate and grip, are secondarily bonded to nents that are fabricated using aluminum
the precured skin panel. alloy sheet.
Page 14
4. Cockpit Floor Panels syntactic foam core. Around the periphery of

each panel, the core is tapered and the panel
(Ref. Figure 7) transitions to form integral monolithic
The cockpit floor panel installation installs a laminate attachment flanges.
combination of composite and metallic panels
B. Metallic Floor Panels
that form the cockpit floor. All panels are
secondary structural components and are (Ref. Figure 7)
stressed panels
The floor panels that are metallic are the
A. Composite Panels
center floor panel, the left and right outboard
(Ref. Figure 7) floor panels, the fixed floor panel, and the
access panel beneath the right crew seat.
The floor panels that are composite are behind
access panel N80, the left and right cyclic floor C. Kick Strips
panel assemblies, and the access panel
beneath the left crew seat. The left and right kick strips cover the
interface between the outboard floor panels
The floor assemblies are composite sandwich and the cockpit sills. These components are
panels that utilize multiple ply skins and installed with screws.
reinforcement plies of graphite/epoxy and
fiberglass/epoxy cocured with either, or a The left and right kick strips are fabricated
combination of, a Nomex honeycomb and/or a from aluminum alloy sheet.
*NOTE: AL AND AR NOMENCLATURE REFER TO LH ACCESS PANEL

PANEL CALLOUTS IN SECTION 060000. (REMOVABLE)
AL138*
RH ACCESS PANEL
(REMOVABLE)
AL138*
LH OUTBOARD FLOOR PANEL

(REMOVABLE)
AL129*
RH OUTBOARD FLOOR PANEL
(REMOVABLE)
AL129* FIXED PANEL
(RIVETED)
RH CYCLIC FLOOR PANEL
ASSEMBLY (RIVETED)
CENTER FLOOR PANEL

(RIVETED)
BATTERY FLOOR
ASSEMBLY (RIVETED)
LH CYCLIC FLOOR PANEL
ASSEMBLY (RIVETED)
9G53-034
Figure 7. Cockpit Floor Panels
Page 15
5. Cabin Floor Panels right forward fuel vent valve access covers,
and the left and right aft fuel vent valve access
(Ref. Figure 8) covers. These panels are fabricated from
The cabin floor panel installation installs a aluminum alloy sheet.
combination of composite and metallic panels
that form the cabin floor. All panels are C. Seat Tracks
secondary structural components and are
stressed panels. (Ref. Figure 8)
A. Composite Panels The seat tracks are installed for attachment of

passenger seats and cargo tie-down rings. The
(Ref. Figure 8) seat tracks are fabricated from standard
The composite panels are the forward floor aluminum alloy seat track extrusions.
panel assembly, the center floor panel assem
bly, and the aft floor panel assembly. D. Kick Strips
The forward, center, and aft floor panel (Ref. Figure 8)

assemblies utilize multiple ply skins and
reinforcement plies of graphite/epoxy and The left and right cabin kick strips cover the
fiberglass/epoxy cocured with a Nomex interface between the outboard floor panels
honeycomb core. Around the periphery of the and the cabin sills of the tub assembly. These
composite panel, the core is tapered and the components are installed with screws. The
panel transitions to form integral monolithic kick strips are fabricated from aluminum alloy
laminate attachment flanges. The composite sheet.
panels in the forward and aft floor panel
assemblies, have monolithic laminate E. Cabin Door Fillets
attachment flanges in the areas of attachment
of the fuel vent valve access covers. The cabin door fillets are located at the lower
aft corners of the left and right cabin door
B. Metallic Panels and Covers openings. The fillets are secondary structural
(Ref. Figure 8) components that complete and reinforce the
joints between the cabin door frame compo
The panels that are metallic are the left and nents and the cabin sills. The fillets are
right outboard floor assemblies, the left and fabricated using aluminum alloy sheet.
Page 16
Original 53-20-00
*NOTE: A, AL, AND AR NOMENCLATURE REFER

RH CABIN KICK STRIP TO PANEL CALLOUTS IN SECTION 060000.
RH AFT ACCESS
COVER ASSEMBLY SEAT TRACK
AR230* (6 PL)
RH OUTBOARD
FLOOR ASSEMBLY
AR165*
RH FORWARD ACCESS LH CABIN KICK STRIP

COVER ASSEMBLY
AR155*
LH AFT ACCESS
COVER ASSEMBLY
SEAL AL230*
SEAL
LH FORWARD ACCESS LH OUTBOARD

COVER ASSEMBLY FLOOR ASSEMBLY
AL155* AL165*
CENTER FLOOR
PANEL ASSEMBLY
A170*
SEAL
(4 PL)
SEAT TRACK
SEAT TRACK
(4 PL)
(4 PL)
AFT FLOOR
PANEL ASSEMBLY
A217*
FORWARD FLOOR
PANEL ASSEMBLY
AR160* SEAL
(3 PL)
SEAL
(3 PL)
9G53-035
Figure 8. Cabin Floor Panels
Page 17
53-20-00 Original
6. Baggage Floor Panels B. Center TieDown Fitting

The center tie-down fitting is installed at the
The center baggage floor panel utilizes forward edge of center floor panel. This fitting
multiple ply skins and reinforcement plies of is machined from aluminum alloy stock.
graphite/epoxy and fiberglass/epoxy cocured
with a Nomex honeycomb core. Around the C. Aft TieDown Plate
periphery of the panel, and in the area of
(Ref. Figure 9)
attachment of the center tie-down fitting and
aft tie-down plate, the core is tapered and the The aft tie-down plate is installed centered at
panel transitions to form monolithic laminate the aft edge of the center floor panel. The aft
attachment flanges. tie-down plate is fabricated from aluminum
alloy sheet.
A. Outboard Baggage Floor Panels
D. TieDown Rings, Clips, and Studs
The left and right outboard baggage floor The tie-down rings and their associated
panels are fabricated from aluminum alloy mounting clips or studs are steel and are of a
sheet. standard load ring configuration.
Page 18
Original 53-20-00
CENTER FLOOR PAN

EL
AFT BAGGAGE
TIEDOWN PLATE
CENTER TIEDOWN
RH OUTBOARD FITTING
FLOOR PANEL
TIEDOWN RING AND

CLIP
(4 PL)
LH OUTBOARD
CARGO TIEDOWN FLOOR PANEL
STUD AND RING
(2 PL)
9G53-036
Figure 9. Baggage Floor Installation

7. Cockpit Console Assembly For information relating to the instrument
(Ref. Figure 1) panel refer to Section 95-00-00. For informa
tion relating to the respective electrical panels
The cockpit console installation installs the refer to Sections 95-00-00 and 96-00-00. For
console assembly that supports the instrument
information relating to the optional avionics
panel. In addition to providing the mounting
base for the instrument panel, the console also equipment refer to Section 97-00-00.
provides the provisions for installation of the
engine/fuel control panel, the electrical/light
ing control panel, the essential bus circuit The console assembly is installed immediately
breaker panel, the utility panel, the four aft of the battery box on the cockpit center
channel DC dimmer, and optional avionic floor panel. Attachment of the assembly is by
equipment. means of bolts.
Page 19
53-20-00 Original
A. Console Assembly components within this installation are

secondary structural components.
The console assembly is a built-up assembly
consisting of seven panel sub assemblies, a Upper and Lower Platform - The upper
tray assembly, receptacle strips, and various and lower platform are composite sandwich
support angles, gussets, and clips. The console panel assemblies that utilizes multiple ply
assembly, and all included components, are skins and reinforcement plies of graphite/
secondary structural components. epoxy and fiberglass/epoxy cocured with a
Nomex honeycomb core. Around the periphery
Within the console assembly, the panel of the panel, the core is tapered and the panel
subassemblies are mechanically fastened transitions to form an edge that is a monolithic
together with rivets to form the exterior laminate.
structure of the assembly. The tray assembly
is riveted between and to the forward vertical Platform Support Brackets The two
panel assemblies along the upper edges to platform support brackets attach the upper
provide the installation and support provisions and lower platform to the cable assemblies.
for the Integrated Instrument Display System These components are fabricated from
(IIDS). The receptacle strips are riveted in aluminum alloy sheet. Attachment to the
their respective positions and provide the upper and lower platform is by screws and
provisions for mounting of the various electri nuts.
cal panels and optional avionics equipment.
Hinges The hinges are fabricated from
The detail components included in panel standard hinge assemblies.
subassemblies within the console assembly, as
well as the support angles, gussets, and clips, Hinge Flap Assembly The hinge flap and
are fabricated from aluminum alloy sheet. bracket are fabricated from aluminum alloy
sheet. The hinge halves and pin are standard
The receptacle strips are standard configura hardware. Components within this subassem
tion instrument receptacle strips that utilize bly are riveted together.
an aluminum alloy extrusion and stainless
steel wire. Cable Assemblies-The cable assemblies are
fabricated using standard 3/32-inch diameter
8. Cabin Door Track wire rope. Standard configuration fork-type
cable terminals and swaged ball ends are
(Ref. Figure 1) installed at each end of the cable assembly.
The left and right upper door tracks are
Stop and Support Brackets, Stiffeners,
installed using rivets. The lower tracks are
and Cleats-These components, with the
installed with bolts. The upper and lower door
exception of the support brackets, are fabri
tracks are machined and formed from alumi
cated from aluminum alloy sheet. The support
num alloy extrusions.
brackets are machined from aluminum alloy
9. Work Platform Assemblies extrusion.
(Ref. Figure 1 and Figure 10) Quarter Turn Fastener Hardware The
quarter turn fastener hardware consists of
The platform assemblies are attached by grommets, studs, and retaining rings. These
riveted hinges, and cable assemblies. All components are standard hardware.
Page 20
Original 53-20-00
QUARTER TURN FASTENER CABLE ASSEMBLY

RECEPTACLE (2 PL) (2 PL)
HINGE (2 PL)
PLATFORM SUPPORT
BRACKET (2 PL)
QUARTER TURN
FASTENER (2 PL)
UPPER PLATFORM
CABLE ASSEMBLY
(2 PL)
QUARTER TURN FASTENER
RECEPTACLE (2 PL) PLATFORM SUPPORT
BRACKET (2 PL)
HINGE (2 PL)
QUARTER TURN
FASTENER (2 PL)
LOWER PLATFORM
NOTE: LH UPPER AND LOWER INSTALLATION

SHOWN, RH OPPOSITE
9G53-042
Figure 10. Work Platforms
Page 21
53-20-00 Original
Page 22
Original 53-20-00
LOWER CENTER AND AFT FUSELAGE

1. Lower Center And Aft Fuselage (10). Use a 10X power glass to inspect the
Inspection faying surfaces of the tailboom attach-
ring assembly and tailboom forward-
A. Airframe Continued Airworthiness end fitting for cracks. No cracks
Inspection permitted.
Defuel the helicopter before you (11). Inspect the roof structure from the
CAUTION remove floor panels AL155, tailboom attach-frame forward for 18
AR155, AL165, AR165, AL230, AR230, or in (45.7 cm).
A235. Damage to the structure can occur if
you remove these panels with fuel in the he (a). Look for rivets that are loose or have
licopter. indications of movement. None
permitted (Ref. Section 53-30-00).
NOTE: Contact MDHI Field Service for
Engineering instructions for a defect. (12). Remove T292 tailboom fairing, L270
left engine exhaust cowling, and R270
(1). Remove AL129, AR129, AL138, and right engine exhaust cowling
AR138 cockpit floor panels (Ref. Section 06-00-00).
(13). Use a 10X power glass to inspect the
(2). Defuel helicopter (Ref. Section upper deck skin from the tailboom
12-00-00). attach-frame forward for 18 in (45.7
cm) for cracks. No cracks permitted
(3). Remove AL165 and AR165 cabin (Ref. Section 53-30-00).
outboard floor panels
(Ref. Section 06-00-00). (14). Install fuel cell and fuel cell liner. (Ref.
Section 28-00-00)
(4). Remove AL250, A235, and AR250
(15). Install the removed floor panels and
baggage floor panels
cowlings (Ref. Section 06-00-00).
(16). Install the tailboom
(5). Carefully remove fuel cell and fuel cell (Ref. Section 53-40-00).
liner to inspect keelbeam-to-tub shell
joint. (Ref. Section 28-00-00) B. Floor Panel Inspection
(6). Inspect the keelbeam-to-tub shell joint (Ref. Figure 201)
for loose rivets or indications of move
(1). Inspect the cockpit, cabin and baggage
ment. None permitted.
floor panels for loose or missing screws.
If keelbeam-to-tub shell joint is None permitted.
CAUTION not riveted, contact MDHI Field (2). Inspect the surface of cockpit, cabin and
Service. baggage floor panels for dents, gouges,
(7). Inspect the landing gear attach-fitting holes, cracks, corrosion and mechanical
to keelbeam-attachments. No defects damage. None permitted.
permitted. (3). Inspect the cockpit, cabin and baggage
floor panels for loose or missing cargo
(8). Inspect all attachments that are less
tie-down fittings. None permitted.
than 12 in (30.5 cm) from the attach-
fittings that are accessible through the (4). Inspect for loose or missing seat tracks.
open floor panels. No defects permitted. None permitted.
(9). Remove the tailboom (5). Inspect the carpet hook tape (velcro) for
(Ref. Section 53-40-00). condition and security.
Page 201
C. Fuselage Exterior Panel Inspection age, and mechanical fasteners that are
loose. None permitted.
(1). Inspect the surface of exterior aircraft
panels for dents, gouges, holes, corro (2). Inspect the A-frame assembly for
sion and apparent damage. None cracks, mechanical damage, and
permitted. mechanical fasteners that are loose.
None permitted.
(2). Inspect the exterior panels for loose or
missing screws. None permitted. (3). Inspect the outboard side of keel beams
for cracks, delamination, and impact
D. Fuselage Cockpit Area Inspection damage. None permitted.
(1). Inspect the cockpit structure for cracks,
(4). Inspect the keel beam to tub joint.
mechanical damage or loose mechanical
fasteners. None permitted. (a). Early Config - Perform a coin tap
(2). Inspect the subfloor structure and test on the bondline between the keel
exterior of tub shell for cracks, mechan beam and fuselage tub assembly (ref.
ical damage, and mechanical fasteners CSP-SPM, Section 20-90-00). Tap
that are loose. None permitted. along the bottom of the fuselage. No
voids permitted.
(3). Inspect FS 155.50 frame assembly in
the cockpit area for cracks, mechanical (b). Current Config - Look for rivets
damage, and mechanical fasteners that that are loose or show signs of
are loose. None permitted. movement. None permitted
E. Fuselage Cabin Area Inspection (5). Inspect FS 230.50 frame assembly in

the cabin area for cracks, mechanical
(1). Inspect FS 155.50 frame assembly in damage, and mechanical fasteners that
cabin area for cracks, mechanic dam are loose. None permitted.
1 9G53-058
1. COCKPIT FLOOR PANELS 3. BAGGAGE FLOOR PANELS

2. CABIN FLOOR PANELS
Page 202
Figure 201. Cockpit, Cabin and Baggage Compartment Floor Panels

(6). Inspect the exterior of the tub shell for
cracks, mechanical damage, and CAUTION
mechanical fasteners that are loose. Screw lengths vary at different locations
None permitted. around each floor panel. Failure to install
the correct length screws may damage
(7). Inspect the landing gear attachment nutplates in the floor substructure or
fittings for cracks, mechanical damage cause loss of screws and possible FOD
and mechanical fasteners that are contamination. During panel removal,
loose. None permitted. keep track of screw locations by pressing
screws into a sheet of cardboard in a pat
tern following the original hardware
F. Aft Fuselage Area and Baggage installation.
Compartment Inspection Use of power tools during removal or
installation of panels and attaching hard
ware may damage nutplates or deform
(1). Inspect the aft FS230.50 frame assem holes in composite panels and covers.
bly in baggage compartment area for
cracks, mechanical damage, and (1). If necessary, remove the copilot
mechanical fasteners that are loose. seat and cockpit carpet
None permitted. (Ref. Section 25-10-00).
(2). Remove the boot from copilot collective
(2). Inspect the outboard side of Keel beams stick and floor panel (Ref. Section
for cracks, delamination, and impact 67-10-00).
damage. None permitted.
(3). Remove the screws and washers.
(4). Lift the cockpit outboard-left floor
(3). Inspect the baggage door frame for
panel AL129 (1) away from the copilot
cracks, mechanical damage, and
collective stick.
mechanical fasteners that are loose.
None permitted. B. Cockpit Outboard Left Floor Panel
Installation
(4). Inspect the exterior of boat tail assem (Ref. Figure 202)
bly for cracks, mechanical damage, and
mechanical fasteners that are loose. (1). Install the cockpit outboard-left floor
None permitted. panel AL129 (1) on the copilot collective
stick.
(2). Install the screws and washers.
2. Cockpit Outboard Left Floor Panel Torque the screws.
(AL129)
(3). Install the boot over collective stick
and secure to the floor panel
A. Cockpit Outboard Left Floor Panel (Ref. Section 67-10-00).
Removal
(4). If necessary, install the cockpit
carpet and copilot seat
(Ref. Figure 202) (Ref. Section 25-10-00).
Page 203
3. Cockpit Outboard Right Floor Panel 4. Cockpit Floor Access Panels (AL138 and
(AR129) AR138)
A. Cockpit Floor Access Panels Removal
A. Cockpit Outboard Right Floor Panel (Ref. Figure 202)
Removal
CAUTION
(Ref. Figure 202) Screw lengths vary at different locations
around each floor panel. Failure to install
nutplates in the floor substructure or
CAUTION cause loss of screws and possible FOD
contamination. During panel removal,
keep track of screw locations by pressing
Screw lengths vary at different locations
the correct length screws may damage installation.
cause loss of screws and possible FOD Use of power tools during removal or
holes in composite panels and covers.
tern following the original hardware NOTE: This task is typical for the removal of
installation. the left or right cockpit floor access panel,
AL138 or AR138.
Use of power tools during removal or (1). Remove the cockpit seats and carpet
installation of panels and attaching hard (Ref. Section 25-10-00).
holes in composite panels and covers. (2). Remove the cabin floor forward panel
assembly A160 (Ref. Section 53-20-00).
(3). Remove the screws and washers from
(1). Remove the pilot seat and cockpit cockpit floor access panel AL138 and
carpet (Ref. Section 25-10-00). AR138 (3 or 4).
(4). Remove the cockpit floor access panel
(2). Remove screws and washers from the AL138.
cockpit outboard-right floor panel B. Cockpit Floor Access Panels Installation
AR129 (2) (Ref. 06-00-00).
(Ref. Figure 202)
NOTE: This task is typical for the installation
B. Cockpit Outboard Right Floor Panel of the left or right cockpit floor access panel,
Installation AL138 or AR138.
(1). Install the cockpit floor access panels
(Ref. Figure 202) AL138 or AR138 (3 or 4).
(2). Install the screws and washers.
Torque the screws.
(1). Install the cockpit outboard-right floor
panel AR129 (2) (Ref. 06-00-00). (3). Install the cabin floor forward panel
assembly, A160 (Ref. Section
53-20-00).
(2). Install the cockpit carpet and pilot seat (4). Install the cockpit carpet and seats
(Ref. Section 25-10-00). (Ref. Section 25-10-00).
Page 204
9G53-102
1. COCKPIT OUTBOARD LEFT FLOOR PANEL (AL129) 3. COCKPIT FLOOR LEFT ACCESS PANEL (AL138)
2. COCKPIT OUTBOARD RIGHT FLOOR PANEL (AR129) 4. COCKPIT FLOOR RIGHT ACCESS PANEL (AR138)
Figure 202. Cockpit Floor Panels
Page 205
53-20-00 Original
5. Cabin Floor Forward And Aft Access 6. Cabin Floor Outboard Panels (AL165 and
Covers (AL155, AR155, AL230 and AR165)
AR230)
A. Cabin Floor Outboard Panel Removal
A. Cabin Floor Access Cover Removal
(Ref. Figure 203)
(Ref. Figure 203)
Defuel the helicopter before you CAUTION
CAUTION remove floor panels AL155,
AR155, AL230, or AR230. Damage to the Defuel the helicopter before you remove
structure can occur if you remove these pan both floor panels AL165 and AR165.
els with fuel in the helicopter. Damage to the structure can occur if
you remove both of these panels with fuel
NOTE: This task is typical for the removal of in the helicopter.
the cabin floor access covers AL155, AR155, Screw lengths vary at different locations
AL230 or AR230. around each floor panel. Failure to install
(1). Defuel helicopter (Ref. Section the correct length screws may damage
12-00-00). nutplates in the floor substructure or
cause loss of screws and possible FOD
(2). If necessary, remove the cabin seats contamination. During panel removal,
and carpet (Ref. Section 25-20-00). keep track of screw locations by pressing
(3). Remove the cabin floor access covers tern following the original hardware
AL155, AR155, AL230 and AR230 installation.
(1, 2, 3 or 4).
Use of power tools during removal or
(a). Remove the screws and washers that installation of panels and attaching hard
attach the covers to the floor panel ware may damage nutplates or deform
and top of the fuel cell. holes in composite panels and covers.
B. Cabin Floor Access Covers Installation NOTE:
(Ref. Figure 203) This task is typical for the removal of the
left or right cabin floor outboard panel,
NOTE: This task is typical for the installation AL165 or AR165.
of the cabin floor access covers AL155,
AR155, AL230 or AR230. You may remove only one of the two out
board floor panels AL165 or AR165 with
(1). Position the cabin floor access covers out defueling the helicopter.
AL155, AR155, AL230 and AR230
(1, 2, 3 or 4) on opening. (1). Defuel helicopter (Ref. Section
12-00-00).
(2). Align the holes of the cover with the
nutplate holes. (2). If necessary, remove cabin seats and
carpet (Ref. Section 25-20-00).
(3). Install the screws that attach the
access cover to the fuel cell. Make sure (3). Remove the screws and washers from
they are flush with the top of the cover. cabin kick strip.
(4). Install the screws and washers that (4). Remove the screws and washers from
attach the access cover to the floor cabin floor outboard panels AL165 or
panel. Torque all screws. AR165 (5 or 6).
(5). If necessary, install the cabin carpet (5). Slide the panel inboard, away from the
and seats (Ref. Section 25-20-00). kick strip too remove.
Page 206
Revision 7 53-20-00
B. Cabin Floor Outboard Panel Installation (2). If necessary, remove the cabin seats
and carpet (Ref. Section 25-20-00).
(Ref. Figure 203)
NOTE: This task is typical for installation of
left or right cabin floor outboard panels, (3). Remove the screws and washers along
AL165 or AR165. the leading edge of the cabin floor
center panel assembly A170 (8).
(1). Position the outboard edge of the cabin
floor outboard panels AL165 or AR165
(5 or 6) under the kick strip and align (4). Remove the left and right cabin floor
the holes. forward access covers AL155 and
AR155 (Ref Section 53-20-00).
(2). Install the screws and washers along
the edge of the panel and kick strip.
Torque screws. (5). Remove the remaining screws and
washers along the edges of the cabin
(3). If necessary, install cabin carpet and floor forward panel assembly A160 (7).
seats (Ref. Section 25-20-00).
7. Cabin Floor Forward Panel Assembly B. Cabin Floor Forward Panel Installation
(A160)
A. Cabin Floor Forward Panel Assembly
(Ref. Figure 203)

(1). Position the cabin floor forward panel
CAUTION assembly A160 (7) with left and right
cabin floor forward access cover (AL155
Defuel the helicopter before you remove and AR155) openings forward.
floor panels AL155 or AR155. Damage to
the structure can occur if you remove
these panels with fuel in the helicopter. (2). Install the screws and washers along
edges of cabin floor forward panel
Screw lengths vary at different locations A160 (7).
nutplates in the floor substructure or (3). Install the left and right cabin floor
cause loss of screws and possible FOD forward access covers AL155 and
contamination. During panel removal, AR155 (Ref. Section 53-20-00).
tern following the original hardware (4). Install the cabin floor center panel
installation. assembly A170 (8).
ware may damage nutplates or deform (5). Torque the screws.
holes in composite panels and covers.
(1). Defuel the helicopter (Ref. Section (6). If necessary, install the cabin carpet
12-00-00). and seats (Ref. Section 25-20-00).
Page 207
53-20-00 Revision 7
8. Cabin Floor Center Panel (A170) (7). Thread the jam nuts down against
backing plates.
A. Cabin Floor Center Panel Removal
(8). Remove the screws that attach the fuel
(Ref. Figure 203) cell to the floor panel.
(9). Loosen the jam nuts until there is no
Special Tools torque pressure from fuel cell rod
(Ref. CSPSPM) (T801). Remove rods with jam nuts and
Item Nomenclature backing plates.
T801 Fuel Cell Rod
(10). Remove the cabin floor center panel
assembly A170 (8) from cabin. Use care
to prevent damage to panel seals.
CAUTION
B. Cabin Floor Center Panel Installation
Defuel the helicopter before you remove
floor panels AL165 and AR165. Damage (Ref. Figure 203)
to the structure can occur if you remove
both of these panels with fuel in the heli Special Tools
copter. (Ref. CSPSPM)
Screw lengths vary at different locations Item Nomenclature
around each floor panel. Failure to install T801 Fuel Cell Rod
cause loss of screws and possible FOD (1). Install the cabin floor forward panel
contamination. During panel removal, assembly A160 (7).
keep track of screw locations by pressing (2). Install the cabin floor aft panel
screws into a sheet of cardboard in a pat assembly A217 (9).
installation. (3). Place the cabin floor center panel
assembly A170 (8) over fuel cell and
align holes in panel with holes in
substructure. Do not install the screws.
holes in composite panels and covers. (4). Thread four fuel cell rod (T801) (with
jam nuts and backing plates) through
(1). Defuel the helicopter (Ref. Section holes in cabin floor center panel A170
12-00-00). (8) and into the access covers on top of
(2). If necessary, remove the cabin seats fuel cell.
and carpet (Ref. Section 25-20-00). (5). Thread the fuel cell rod jam nuts down
(3). Remove the left and right cabin floor against backing plates too pull the fuel
outboard panels AL165 and AR165 cell up against the floor panel.
(5 and 6). (6). Install the screws through the floor
panel and into the fuel cell access
(4). Remove the screws and washers along
covers.
the edges of the cabin floor center panel
assembly A170 (8). (7). Remove the fuel cell rods.
(5). Remove the vapor plugs (10) from the (8). Install vapor plugs (10).
holes in the cabin floor center panel
(9). Install screws and washers around
assembly A170 (8).
edges of panel A170 (8).
(6). Thread fuel cell rod (T801) with jam (10). Torque screws.
nuts and backing plates into four holes
in panel (8). Engage threads into the (11). If necessary, install cabin carpet and
fuel cell access covers. seats (Ref. Section 25-20-00).
Page 208
Revision 7 53-20-00
9. Cabin Floor Aft Panel Assembly (A217) (3). Remove the screws and washers along
trailing edge of cabin floor center panel
A. Cabin Floor Aft Panel Assembly Removal assembly A170 (8).
(4). Remove the left and right cabin floor
(Ref. Figure 203) aft access covers AL230 and AR230
CAUTION (5). Remove the baggage floor center panel
A235 (Ref. Section 53-20-00).
floor panels AL230 or AR230. Damage to B. Cabin Floor Aft Panel Installation
the structure can occur if you remove
these panels with fuel in the helicopter. (Ref. Figure 203)
Screw lengths vary at different locations (1). Position the cabin floor aft panel A217
around each floor panel. Failure to install (9) with left and right cabin floor aft
the correct length screws may damage access cover (AL230 and AR230)
nutplates in the floor substructure or openings aft.
(2). Install the screws and washers along
forward edge of panel A217 (9).
screws into a sheet of cardboard in a pat (3). Install the left and right aft access
tern following the original hardware covers AL230 and AR230
installation. (Ref. Section 53-20-00).
Use of power tools during removal or (4). Install the baggage floor center panel
installation of panels and attaching hard A235 (Ref. Section 53-20-00).
holes in composite panels and covers. (5). Install the screws and washers along
the trailing edge of cabin floor center
(1). Defuel the helicopter (Ref. Section panel A170 (8).
12-00-00).
(6). Torque the screws.
(2). If necessary, remove the cabin seats (7). If necessary, install the cabin carpet
and carpet (Ref. Section 25-20-00). and seats (Ref. Section 25-20-00).
Page 209
53-20-00 Revision 7
4
3
8
6 9
10
9G53-103
1. CABIN FLOOR LEFT FORWARD ACCESS COVER 5. CABIN FLOOR LEFT OUTBOARD PANEL (AL165)
(AL155) 6. CABIN FLOOR RIGHT OUTBOARD PANEL (AR165)
2. CABIN FLOOR RIGHT FORWARD ACCESS COVER 7. CABIN FLOOR FORWARD PANEL ASSEMBLY (A160)
(AR155) 8. CABIN FLOOR CENTER PANEL ASSEMBLY (A170)
3. CABIN FLOOR LEFT AFT ACCESS COVER (AL230) 9. CABIN FLOOR AFT PANEL ASSEMBLY (A217)
4. CABIN FLOOR RIGHT AFT ACCESS COVER (AR230) 10. VAPOR PLUG
Figure 203. Cabin Floor Panels
10. Baggage Floor Center Panel (A235)

A. Baggage Floor Center Panel Removal
(Ref. Figure 204) floor panel A235. Damage to the struc
ture can occur if you remove this panel
CAUTION with fuel in the helicopter.
Screw lengths vary at different locations
around each floor panel. Failure to install (1). Defuel the helicopter
keep track of screw locations by pressing (2). If necessary, remove the baggage
screws into a sheet of cardboard in a pat compartment carpet
tern following the original hardware (Ref. Section 25-50-00).
installation.
installation of panels and attaching hard (3). Remove the screws and washers that
ware may damage nutplates or deform attach the baggage floor center panel
holes in composite panels and covers. A235 (1) to substructure.
Page 210
Revision 7 53-20-00
B. Baggage Floor Center Panel Installation NOTE: This task is typical for the removal of
the left and right baggage compartment
(Ref. Figure 204) floor panels AL250 and AR250.
(1). Install the baggage floor center panel
A235 (1) to the substructure with
screws and washers. 12-00-00).
(2). If necessary, install the baggage (2). If necessary, remove the baggage
compartment carpet compartment carpet
11. Baggage Floor Outboard Panels (AL250 (3). Remove the baggage floor center panel
and AR250) A235 (Ref. Section 53-20-00).
A. Baggage Floor Outboard Panels Removal (4). Remove the screws and washers that
attach the left and right baggage floor
(Ref. Figure 204) outboard panels AL250 and AR250
(2 or 3) to substructure.
CAUTION
B. Baggage Floor Outboard Panels
Screw lengths vary at different locations Installation
the correct length screws may damage (Ref. Figure 204)
cause loss of screws and possible FOD NOTE: This task is typical for installation of
contamination. During panel removal, left and right baggage compartment floor
keep track of screw locations by pressing panels AL250 and AR250.
tern following the original hardware (1). Install the left and right baggage floor
installation. outboard panels AL250 and AR250
Use of power tools during removal or (2 or 3) to substructure with screws and
installation of panels and attaching hard washers.
ware may damage nutplates or deform (2). Install the baggage floor center panel
holes in composite panels and covers. A235 (Ref. Section 53-20-00).
floor panel A235. Damage to the struc (3). If necessary, install the baggage
ture can occur if you remove this panel compartment carpet
with fuel in the helicopter. (Ref. Section 25-50-00).
Page 211
53-20-00 Revision 7
3
2
9G53-101
1. BAGGAGE FLOOR CENTER PANEL (A235) 3. BAGGAGE FLOOR RH OUTBOARD PANEL (AR250)
2. BAGGAGE FLOOR LH OUTBOARD PANEL (AL250)
Figure 204. Baggage Compartment Floor Panels
12. Cabin Step (Optional) B. Cabin Step Installation
(Ref. Figure 205)
A. Cabin Step Removal
Item Nomenclature
C237 Sealant
NOTE: This task is typical for removal of the
left and right cabin steps.
NOTE: This task is typical for installation of
the left and right cabin steps.
(1). Remove the outboard floor panel AL165
or AR165 (Ref. Section 53-20-00). (1). Remove the cabin step plugs (5) if
installed.
(2). Remove the nuts (1), washers (2) and (2). Remove the outboard floor panel AL165
bolts (3) that attach the cabin step (4) or AR165 (Ref. Section 53-20-00).
to airframe. (3). Slide the boot (6) over each tube end of
step (4).
(3). Remove sealant from the step to (4). Insert the tube ends of cabin step
airframe interface. through holes in fuselage and align bolt
holes.
(4). Install the cabin step plugs (5) if the (5). Make sure both step support saddles (7)
cabin step is permanently removed. are looped below the cabin step.
(6). Install the step on the frame with bolts
(5). Install the outboard floor panel AL165 (3), washers (2) and nuts (1). Torque
or AR165 (Ref. Section 53-20-00). the nuts.
Page 212
Revision 7 53-20-00
Sealant (C237) B. Cabin Step Plug Installation

(Ref. Figure 205)
(Ref. CSPSPM)
(7). Apply sealant (C237) to the faying
Item Nomenclature
surfaces of the boots and airframe.
C237 Sealant
13. Cabin Step Plug
Sealant (C237)
A. Cabin Step Plug Removal
(Ref. Figure 205)
When removing sealant and

CAUTION plug use care to avoid damaging NOTE: This task is typical for installation of
composite airframe skin. the forward, aft, left side and right side cab
in step plugs.
NOTE: This task is typical for removal of the (1). Apply sealant (C237) to faying surfaces
forward, aft, left side and right side cabin
of plug (5) and airframe.
step plugs.
(2). Press the plug into the hole in the
(1). Remove sealant from the plug to airframe.
airframe interface.
(3). Remove sealant from the plug to
(2). Remove the cabin step plug (5). airframe interface.
Page 213
53-20-00 Revision 7
2 1
2
3
1
2
2
3
6
7
6 4
5 (2PL)
9G53-118
1. NUT 5. CABIN STEP PLUG
2. WASHER 6. BOOT
3. BOLT 7. SUPPORT SADDLE
4. CABIN STEP
Figure 205. Cabin Step (Optional)
Page 214
Original 53-20-00
Section
533000
Fuselage Upper
Deck and Aft Area
FUSELAGE UPPER DECK AND AFT AREA

1. Fuselage Lower, Center, and Aft Area Additional components include various
General hardware such as an anchor plate, receptacles,
(Ref. Figure 1) and standard hardware.
The major subassemblies or installations that Aft Fillet Fairings and Ribs The aft fillet
are contained in this area of the fuselage are fairings and ribs are secondary structural
the roof assembly, the firewall build-up components. The associated ribs provide
assembly and installation, the engine deck secondary attachment provisions and structur
thermal insulation installation, the NOTAR al support for the fillet faring components.
inlet screen assembly, the forward duct
installation, the NOTAR diverter-stator and The left and right fillet fairings are composite
diverter plate installation, the forward fairings components that are fabricated as monolithic
and doors installation, and the aft cowling laminates using multiple plies of fiberglass/
installation. epoxy. The support ribs are fabricated from
aluminum alloy sheet.
2. Roof Assembly
(Ref. Figure 2)
The components that are included in the roof
assembly are the roof structure assembly,
intermediate and aft cowling attachment
angles, aft fillet fairing and ribs, rear fuselage
shell assemblies, the anti-torque fan support
structure and aft duct, and the tailboom
attachment ring assembly.
Page 1
53-30-00 Original
NOTAR INLET
SCREEN ASSEMBLY
AFT COWLING
INSTALLATION
FORWARD FAIRINGS AND

DOORS INSTALLATION
ENGINE DECK
THERMAL INSULATION
INSTALLATION (NOT VISIBLE
IN THIS VIEW)
ROOF
ASSEMBLY
FIREWALL BUILDUP
ASSEMBLY
900 CONFIG
FORWARD DUCT INSTALLATION AND NOTAR DIVERTER
STATOR AND DIVERTER PLATE INSTALLATION
(NOT VISIBLE IN THIS VIEW)
NACA CONFIG
9G53038A
Figure 1. Fuselage Upper Deck and Aft Area
Page 2
Original 53-30-00
RH AFT COWL ANTITORQUE FAN

RH INTERMEDIATE COWL ATTACHMENT ANGLE SUPPORT STRUCTURE
ATTACHMENT ANGLE (RH SHOWN, LH OPPOSITE)
(RH SHOWN, LH OPPOSITE) ANTITORQUE FAN
AFT DUCT ASSEMBLY
ROOF STRUCTURE
ASSEMBLY
LH AFT
FILLET FAIRING
(LH SHOWN,
RH OPPOSITE)
LH REAR FUSELAGE
SHELL ASSEMBLY
(LH SHOWN, RH OPPOSITE)
9G53045
Figure 2. Roof Assembly
Page 3
53-30-00 Original
A. Roof Structure Assembly B. Engine Deck, Aft Deck, and Aft Outer
Deck Skins
(Ref. Figure 3)
(Ref. Figure 3)
The roof structure assembly forms the load
The engine deck, aft deck, and aft outer deck
bearing structure that supports the main
skins complete the deck skin aft of the forward
rotor, transmission drive, and propulsion
roof deck skin for the roof assembly. These
subsystems.
components are primary structural compo
The major components contained within the nents and function as the shear panels for the
roof structure assembly are the A-Frame roof assembly.
assembly, FS 230.50 upper aft frame assembly, The left and right titanium deck skins are
the forward and mid roof installations, aft installed in the three deck areas contained
deck structure assembly, roof beam installa within the engine compartment firewalls. The
tions, engine deck, aft deck, aft deck outer left and right aluminum engine deck skins are
skins, cabin seat forward upper support installed immediately inboard and aft of the
assembly, support installations for the flight engine compartment firewalls. The titanium
controls, environmental control system (ECS), deck skins are fabricated from .016-inches
hydraulic subsystems, firewall and flight thick titanium alloy sheet. The aluminum deck
controls support channels, and forward cowl skins are fabricated from .020-inches thick
attachment angles. aluminum alloy sheet.
Secondary components include deck skin The left and right aft deck and aft outer deck
doublers and stiffeners, tension, shear and skins are located aft of the anti-torque fan
secondary attachment clips and cleats, support structure. The aft deck and aft outer
reinforcement gussets, and standard hard deck skins are fabricated from .020-inches
ware. thick aluminum alloy sheet.
Page 4
Original 53-30-00
LH AFT
DECK SKIN
RH ENGINE RH AFT
DECK SKIN RH AFT DECK SKIN
RH TITANIUM OUTER SKIN
DECK SKIN
(FWD DECK SKIN,

COMPONENT OF MID
ROOF INSTALLATION)
LH AFT
OUTER SKIN
LH ENGINE
DECK SKIN
(LH AFT OUTER SKIN,

COMPONENT OF LH ROOF
BEAM INSTALLATION,
RH OPPOSITE)
(LH OUTER SKIN,
LH TITANIUM
COMPONENT OF LH ROOF
DECK SKIN
BEAM INSTALLATION,
RH OPPOSITE)
ROOF HANDHOLD
ASSEMBLY
(4 PL)
9G53044
Figure 3. Roof Structure Assembly
Page 5
53-30-00 Original
C. AFrame Assembly Mast Fitting Assemblies The left and right

forward mast fitting assemblies are primary
(Ref. Figure 5 and Figure 4) structural components that are the provisions
The A-frame assembly supports the main for attachment of the forward support trusses
rotor and drive system loads in all three of the static mast assembly. Each mast fitting
directions. Main rotor and drive system loads assembly is installed with pins and collars.
are transferred to this support structure by the
left and right forward mast fitting assemblies.
Each mast fitting assembly consists of a
The components contained within the A-frame machined fitting and flanged bushing. The
assembly are the A-frame center beam, the mast fittings are machined from aluminum
left and right A-frame vertical legs, the left alloy stock. The flanged bushings are ma
and right mast fitting assemblies, and shear chined from corrosion resistant steel. The
cleats. bushings are press fit and then reamed to final
hole size.
AFrame Center Beam and Vertical Legs The
A-frame center beam and left and right
vertical legs are primary structural compo
nents. These three components are joined Shear Cleats The shear cleats are secondary
within this assembly by pins and collars. structural components that are utilized for
attachment of the lower ends of the vertical
The A-frame center beam and left and right legs to the general tub assembly. These shear
vertical legs are machined from aluminum cleats are fabricated from aluminum alloy
alloy stock. sheet.
RH FORWARD MAST
FITTING ASSEMBLY
LH FORWARD MAST
FITTING ASSEMBLY
CENTER BEAM
RH VERTICAL LEG
LH VERTICAL LEG
9G53046
Figure 4. AFrame Assembly
Page 6
Original 53-30-00
D. Forward Roof Structure Installation The longeron doublers, deck skin stiffeners,
reinforcing strap and doubler, and attachment
(Ref. Figure 5) cleats and clips are fabricated from aluminum
alloy sheet.
The major components within this installation
are the forward roof deck and FS 166.749 roof Forward Roof Intercostal The forward roof
deck doublers, forward longerons, forward roof intercostal is a primary structural component
intercostal, FS 155.50 roof angle, and RBL that supports the hydraulic system compo
8.50 reinforcing angle. nents mounted on the upper deck. This
component resembles a longeron and is
Secondary components include longeron installed inboard of the longeron at LBL 18.50.
doublers, deck skin stiffeners, a reinforcing Structural attachment of this component is
strap, and attachment cleats and clips. similar to the longerons.
Forward and FS 166.749 Roof Deck Doublers The forward roof intercostal is formed with
The forward and FS 166.749 roof deck integral flanges and flanged lightening holes.
doublers are installed as secondary structural This component is fabricated from aluminum
components alloy sheet.
These two doublers function as deck skin Flight Controls Support Roof Structure
reinforcements to support the upper deck Installation The primary structural compo
mounted flight controls. Both doublers are nents within this installation are the flight
fabricated from aluminum alloy sheet. controls support intercostals. The two longitu
dinal intercostals attach to the FS 155.50
Forward Longerons Five forward longerons frame assembly, and eight lateral intercostals.
are primary structural components that The eight lateral intercostals attach to the
support upper deck loads in the vertical and longerons of the forward structure installation.
longitudinal directions. The forward longerons In addition, the upper flanges of each of these
are fabricated from aluminum alloy sheet. intercostals are attached to the forward roof
deck skin. The intercostals are fabricated from
FS 155.50 Roof Angle and RBL 8.50 Reinforc- aluminum alloy sheet.
ing Angle The FS 155.50 roof angle and the
RBL 8.50 reinforcing angle are secondary Secondary structural components included
structural components that provide the within this installation are the tension and
forward attachment provisions for the forward attachment clips and cleats, reinforcement and
roof deck skin. stiffening angles, and A-frame radius blocks.
Both the FS 155.50 roof angle and the RBL
8.50 reinforcing angle are fabricated from The attachment, tension clips, cleats, and
aluminum alloy. reinforcement angles are fabricated from
aluminum alloy sheet. The radius blocks are
machined from aluminum alloy stock.
Longeron Doublers, Deck Skin Stiffeners,
Reinforcing Strap, Attachment Cleats and
Clips The longeron doublers, deck skin ECS Roof Support Installations All compo
stiffeners, reinforcing strap, and attachment nents installed within this support installation
cleats and clips are secondary structural are secondary structural components, and
components. The longeron doubler reinforce provide attachment for components of the
the webs of the longerons in the areas of the ventilation and optional air conditioning
cutouts for the ventilation ducting. The subsystems.
reinforcing strap, a doubler, and the attach
ment cleats and clips are installed to provide The intercostals, clips, and cleats are fabri
local area reinforcement for secondary cated from aluminum alloy sheet. The radius
attachment of additional deck mounted blocks are machined from aluminum alloy
hydraulic components. stock.
Page 7
53-30-00 Original
Hydraulics Roof Support Installation The longerons are primary structural components
hydraulics roof support installation installs that support upper deck loads in the vertical
additional secondary structural components and longitudinal directions.
and related standard hardware to the roof
structure. The additional components provide
the attachment for the left and right manifold The roof longerons, the shear cleats, and the
/ reservoirs and the optional hand pump of the attachment cleats are fabricated from alumi
hydraulic subsystem. num alloy sheet.
This installation installs two intercostals and
associated clips, between LBL and RBL 7.75 Longeron Reinforcing Angles The longeron
and 18.50. Intercostals, stiffeners, gussets, and reinforcing angles are primary structural
attachment cleats are installed immediately
installed at the the aft ends of the LBL and
aft of FS 155.50 between BL 0.00 and LBL
RBL 18.50 longerons. The longeron reinforcing
7.75 for support of the hydraulic hand pump.
angles are fabricated from aluminum alloy
The components within this installation are
sheet.
Forward Cowl Attachment Angles The
forward cowl attachment angles are secondary Cabin Seat Forward Upper Support Assem-
structural components. The forward cowl bly Within the roof assembly, the cabin seat
attachment angles are fabricated from forward upper support assembly contains the
aluminum alloy sheet. secondary structural components that provide
the attachment for the passenger seats.
E. Mid Roof Installation
(Ref. Figure 5) This assembly includes bracket assemblies,
The major components within this installation cleat assemblies, bearing plates, and anchor
are the forward roof deck skin, roof longerons, plates. These components are installed on the
longeron reinforcing angles, left and right aft underside of the horizontal webs of the left and
engine attachment assemblies, engine right roof beams, and against the lower
mounting intercostals, mid roof straps, flanges of the longeron components of the
longeron and bridging doublers, FS 220.50 forward roof structure.
deck skin and inboard longeron deck skin
doublers, and fuel valve mount bracket
assemblies. The detail components within this assembly
are fabricated from aluminum alloy sheet. All
Secondary components include deck skin components are installed with rivets.
stiffeners, lower flange channels, and standard
hardware.
Aft Engine Attachment Assemblies The
Forward Roof Deck Skin The forward roof
left-hand and right-hand aft engine attach
deck skin is the upper deck skin located
ment assemblies installed within this installa
immediately aft of the FS 155.50 frame
tion are primary structural components that
assembly and forward of the engine inlet
plenums. The skin extends to the left and right provide the provisions for attachment of the
roof beams. This component is a primary forward leg of the bipod engine mounts.
structural component and functions as the
shear panel for the roof structure. The forward
roof skin is fabricated from .020-inches thick Each aft engine attachment assembly consists
aluminum alloy sheet. of a fitting and a flanged bushing machined
from titanium alloy stock. The flanged
Roof Longerons Five roof longerons are bushings are standard corrosion resistant
utilized within this assembly to join the FS steel. The bushings are press fit installed into
230.50 upper aft frame assembly, the A-frame each fitting, and then reamed to final hole
assembly, and the forward deck skin. These size.
Page 8
Original 53-30-00
Engine Mounting Intercostals The engine The deck skin doublers and inboard longeron
mounting intercostals are primary structural deck skin doublers are fabricated from
components. These components are fabricated aluminum alloy sheet.
from aluminum alloy sheet.
Deck Skin Stiffeners and Lower Flange
Valve Mount Bracket Assemblies The valve Channels The deck skin stiffeners and
mount bracket assemblies and intercostals are channels are installed on the underside of the
secondary structural components that provide forward roof deck skin.
the for mounting of a left and a right engine
Two lower flange channels function to support
fuel supply frangible self-sealing valve.
and stabilize the longerons. The deck stiffeners
The left bracket assembly is located immedi and lower flange channels are fabricated from
ately outboard of the LBL 18.50 longeron aluminum alloy sheet.
between FS 224.53 and FS 227.53. The right F. Aft Deck Structure Assembly
bracket assembly is located immediately
inboard of the RBL 7.75 longeron between FS (Ref. Figure 5)
216.50 and FS 219.50.
The major components contained within the
Each valve mount bracket assembly consists of aft deck structure assembly are the aft section
a valve mount bracket, two tension (mounting) longerons, aft deck sub-longerons, aft deck
clips, and standard hardware. The bracket, intercostals, aft deck subframe, aft deck insert
tension clips, and intercostals are fabricated frame assembly, and aft deck engine attach
from aluminum alloy sheet. ment assemblies.
Mid Roof Straps The mid roof straps are Secondary components include bearing and
secondary structural components that function doubler plates, radius blocks, attachment,
as doublers for the forward roof deck skin. The reinforcing, and stiffening angles, doubler and
straps are located on the forward deck skin attachment cleats, and hardware.
approximately at FS 200 and FS 206. The mid Aft Section Longerons The aft section
roof straps are fabricated from aluminum alloy longerons are primary structural components
sheet. that support upper deck loads in the vertical
and longitudinal directions.
Longeron and Bridging Doublers The
longeron and bridging doublers are secondary The four longerons contained within this
structural components that are installed at the assembly are located at LBL and RBL 18.50,
forward ends of each of the roof longerons. The and at LBL and RBL 7.75. The forward ends
longeron and bridging doublers are fabricated of these longerons terminate and are attached
from aluminum alloy sheet. to the FS 230.50 upper aft frame assembly.
The aft ends of the LBL and RBL 7.75
FS 220.50 Deck Skin and Inboard Longeron longerons terminate and attach to the aft deck
Deck Doublers The left and right FS 220.50 insert frame assembly.
deck skin doublers and the left and right
inboard longeron deck doublers are secondary The aft section longerons, and secondary
structural components that are installed near attachment cleats or angles are fabricated
the aft edge of the forward roof deck skin. from aluminum alloy sheet.
Page 9
53-30-00 Original
Aft Deck SubLongerons The aft deck Aft Deck Engine Attachment Assemblies -
sub-longerons are primary structural compo The left and right aft engine attachment
nents that provide support for the engine assemblies are primary structural components
attachment assemblies and the directional that provide the provisions for attachment of
controls of the flight controls subsystem. the two aft legs of the bipod engine mounts.
The sub-longerons and secondary attachment Each aft engine attachment assembly consists
angles are fabricated from aluminum alloy of a fitting and a flanged bushing. The aft
sheet. engine attachment fittings are machined from
titanium alloy stock. The flanged bushings are
Aft Deck Intercostals The aft deck intercos corrosion resistant steel. The bushings are
tals are primary structural components and press fit installed into each fitting, and then
are located at FS 235.69 and FS 245.25. reamed to the final hole dimension.
The aft deck intercostals provide the attach Flight Controls Aft Support Channel The
ment and support for engine attachment flight controls aft support channel is a primary
assemblies. structural component of the roof structure
The intercostals, the bearing plates, and assembly that provides attachment and
attachment angles are fabricated from support for the directional controls of the flight
aluminum alloy sheet. controls subsystem. The flight controls aft
support channel is fabricated from aluminum
Aft Deck Subframe The aft deck subframe is alloy sheet.
a primary structural component that bridges
the left and right longerons and aft deck Firewall Channels The left and right firewall
structure. In addition, this member also channels are primary structural components
provides for attachment of the engine attach that support the firewall build-up assembly.
ment assemblies. The firewall channels are fabricated from
aluminum alloy sheet.
The subframe and attachment angles are
fabricated from aluminum alloy sheet. Cowl Attachment Angles The cowl attach
ment angle components of the roof assembly
Aft Deck Insert Frame Assembly The aft are secondary structural components that
deck insert frame assembly is a primary provide the lower attachment for the engine
structural component. To facilitate removal of air inlet screen assemblies (or optional inlet air
the anti-torque drive shaft, this frame particle separators), the engine cowl assem
assembly is retained by bolts. The frame insert blies, and the exhaust ejector cowl assemblies.
and doublers are fabricated from aluminum The cowl attachment angles are fabricated
alloy sheet. from titanium alloy sheet.
Page 10
Original 53-30-00
G. Roof Beam Installations tive engine deck, aft outer, and aft deck skins,
and the rear fuselage shell assembly. The aft
(Ref. Figure 3 and Figure 5) deck angle is fabricated from aluminum alloy
sheet.
The major components contained within each
roof beam installation are the vertical and Track Pockets The track pockets are
horizontal webs, roof beam and handhold secondary structural components that form
support ribs, extrusion angle, aft deck angle, evironmental closeouts at the cutouts in the
track pockets, forward and aft outer roof beam forward outer skin for the upper cabin door
skins, and rear stay deck fitting assembly. track.
Secondary components include cowl support The track pockets are composite components
clips and doublers, door track brackets and that are fabricated as monolithic laminates.
cleats, and roof beam attachment cleats, Each track pocket is fabricated using multiple
doublers, splice components, and standard plies of graphite/epoxy and fiberglass/epoxy.
hardware. The doublers are fabricated from aluminum
alloy sheet.
Vertical and Horizontal Webs The vertical
and horizontal web components are primary Forward and Aft Outer Roof Beam Skins The
structural components that when combined roof beam forward and aft outer skins are
with the roof beam outer skins form the primary structural components that when
triangular shaped roof beam. The vertical and combined with the roof beam vertical and
horizontal webs are fabricated from aluminum horizontal web components form the triangu
alloy sheet. lar shaped beam.
Roof Beam and Handhold Support Ribs The The forward roof beam skin is installed from
roof beam and handhold support ribs are the 155.50 frame and terminates immediately
secondary structural components that provide forward of the FS 230.50 frame. The aft roof
attachment for the vertical and horizontal beam skin is installed from the aft end of the
webs, and the outer roof beam skins. forward skin to FS 268.00. The roof beam
forward and aft outer skins are fabricated
The roof beam and handhold support ribs are from aluminum alloy sheet.
installed internal to the triangular shaped
sub-structure formed by the vertical webs, Rear Stay Deck Fitting Assembly The rear
horizontal webs, and the outer skins. stay deck fitting assembly is a primary
structural component that provides for
The handhold support ribs are installed at FS attachment of the rear stay assembly for the
160.63, 167.60, 218.50, and 225.47. Roof beam left or right engine.
support ribs are installed at FS 188.00,
197.66, 207.36, 230.50, and 249.78. The roof The rear stay deck fitting assembly consists of
beam and handhold support ribs are fabri a fitting and a flanged bushing. The fitting is
cated from aluminum alloy sheet. machined from titanium alloy stock. The
flanged bushing is a standard corrosion
Extrusion Angle The extrusion angle is a resistant steel component. The bushing is
primary structural component that is installed press fit installed into the fitting, and then
between the vertical and horizontal web reamed to the final hole dimension.
components. The extrusion angle extends
from the FS 155.5 frame to FS 225,0. The Secondary Components The secondary
extrusion angle is machined from aluminum components include cowl support clips and
alloy extrusion. doublers, door track brackets and cleats, roof
beam attachment cleats, doublers, and web
Aft Deck Angle The aft deck angle is a splice components are secondary structural
primary structural component that functions components. These components are fabricated
as the attachment angle between the respec from aluminum alloy sheet.
Page 11
53-30-00 Original
RH FIREWALL
SUPPORT CHANNEL
AFT DECK STRUCTURE
ASSEMBLY LH FIREWALL
RH ROOF BEAM SUPPORT CHANNEL
INSTALLATION
MID ROOF STRUCTURE

INSTALLATION
FLIGHT CONTROLS
LH ROOF BEAM
SUPPORT INSTALLATION
INSTALLATION
FWD ROOF STRUCTURE

INSTALLATION
FS 230.50 UPPER
FRAME ASSEMBLY
AFRAME ASSEMBLY
NOTE: UPPER DECK AND ROOF BEAM SKINS

NOT SHOWN FOR CLARITY.
9G53043
Figure 5. Roof Structure Beam and Frame Assembly
Page 12
Original 53-30-00
H. FS 230.50 Aft Frame Assembly The fittings are attached to the deck skin by
rivets.
Each mast fitting assembly consists of a fitting
The FS 230.50 upper aft frame assembly is and a flanged bushing. The mast fittings are
joined to the left and right FS 230.50 lower machined from aluminum alloy stock. The
frame assemblies. This is a built-up assembly flanged bushings are machined from corrosion
that is primary structure and provides support resistant steel. The bushings are press fit
for the main rotor and drive system loads in all installed into each fitting, and then reamed to
three directions. Main rotor and drive system the final hole dimension.
loads are transferred by the left and right aft
mast fitting assemblies and the left and right Static Mast Channels The left and right
engine attachment assemblies. static mast channels provide support for the
left and right mast fitting assembly. Each
Frame Web The frame web is a primary channel attaches through the FS 230.50 frame
structural component. The web is the shear web to the aft side of the mast fitting assem
panel for the upper section of the FS 230.50 bly. The channels are also attached to the
frame, and is the platform onto which all vertical channels and roof beams. Attachment
components within this assembly are fastened. is by pins and collars or rivets. The channels
This web is fabricated from aluminum alloy are machined from aluminum alloy stock.
sheet.
Engine Attachment Assemblies The four
Horizontal Channel Frame The horizontal engine attachment assemblies are primary
frame is a secondary structural component structural components. The assemblies provide
that is the upper frame member for the for attachment of the forward leg of the tripod
through opening between the baggage engine mounts and the aft leg of the bipod
compartment and the passenger cabin. The engine mounts. Attachment is by pins and
horizontal frame is fabricated from aluminum collars.
alloy sheet.
Each engine attachment assembly consists of a
Aft Frame ZSection The aft frame Z-sec fitting and a flanged bushing. The engine
tion is a primary structural component that attachment fittings are machined from
functions as a longitudinal support member. In titanium alloy stock. The flanged bushings are
addition to providing support for the deck corrosion resistant steel. The bushings are
structure, this component provides attachment press fit installed into each fitting, and then
of the anchor plates used for upper attachment reamed to the final hole dimension.
of the aft row of passenger seats. The aft
frame Z-section is fabricated from aluminum Fuel Valve Support Bracket Assemblies
alloy sheet. The fuel valve support bracket assembly is a
secondary structural component that provides
Vertical Channels The left and right vertical for mounting of the left and right fuel shutoff
channels are primary structural components valve assembly. The bracket is attached by
that support vertical and longitudinal loads. rivets. The valve support bracket assembly is
These components form the vertical edges of fabricated from aluminum alloy sheet.
the through opening between the baggage
compartment and cabin. The left and right Doublers, Gussets, Angles, Channel Frames
vertical channels are fabricated from alumi and Brackets The doublers, gussets,
num alloy sheet. stiffening angles, channel frames and brackets
are secondary structural components. These
Mast Fitting Assemblies The left and right components are fabricated from aluminum
mast fitting assemblies are primary structural alloy sheet.
components that provide for attachment of the
static mast assembly and aft support trusses. Tie-down Rings and Studs - A tie-down
ring and stud is installed into the left and
The mast fitting assemblies are attached to right side of the FS 230.50 upper frame
the FS 230.50 frame web at LBL and RBL assembly. The tie-down rings are steel and are
18.50 and roof longerons by pins and collars. standard load ring hardware.
Page 13
53-30-00 Original
RH ENGINE ATTACHMENT
ASSEMBLIES
LH ENGINE ATTACHMENT
ASSEMBLIES
LH AFT MAST
FITTING ASSEMBLY
LH STATIC MAST CHANNEL

FRAME WEB (RH OPPOSITE)
AFT FRAME ZSECTION
RH OUTBOARD
(ATTACHMENT) CHANNEL
RH VERTICAL CHANNEL
LH OUTBOARD (ATTACHMENT)
CHANNEL
RH VERTICAL CHANNEL
9G53047
Figure 6. FS 230.50 Upper Aft Frame Assembly

3. Firewall BuildUp Assembly and angles, and the components that are utilized to
Installation form the forward and aft seal land assemblies
are formed and fabricated from either tita
(Ref. Figure 7) nium alloy or corrosion resistant steel.
Fastening is by monel rivets.
The firewall build-up installation installs the
firewall build-up assembly, the NOTAR Upper Portion Inlet Assemblies The left and
inlet assembly, the middle NOTAR inlet right upper portion inlet assemblies provide
duct assembly, and the engine deck thermal seal lands for installation of the forward and
insulation. aft engine firewall to plenum seals.
The components within the firewall build-up The panels, attachment and stiffening angles,
assembly provide for mounting and attach and the seal land components are fabricated
ment of the NOTAR inlet screen assembly, from either titanium alloy or corrosion
and the left and right air inlet screens or resistant steel material. Fastening is by monel
optional inlet air particle separators, engine rivets. Attachment of each upper portion inlet
cowls, secondary exhaust nozzles, and exhaust assembly to the riveted inlet panels is by
ejector cowls. screws and bolts.
A. Firewall BuildUp Assembly Firewall Panels The firewall panels include

the forward firewall assembly, the left and
Inlet Panels The inlet panels for the left and right inboard firewall assemblies, and the left
right engines form the forward and aft vertical and right aft firewall assemblies. The inboard
walls of the air inlet plenum. The inlet panels, and aft firewall assemblies combine with
the associated attachment and stiffening titanium deck skins, engine deck thermal
Page 14
Original 53-30-00
insulation, and associated engine cowl 4. Engine Deck Thermal Insulation

assemblies, to form the required fire proof Installation
enclosure that contains the hot section and the (Ref. Figure 7)
primary exhaust nozzle for each engine.
The engine deck thermal insulation installa
tion installs the fireproof and heat insulating
Forward Firewall Assembly The forward blankets onto the left and right engine deck
firewall assembly is mounted at FS 240.00, skins. Each installation includes a forward,
aft, and inboard thermal insulation compo
centered between the left and right forward
nent. All components are retain by sections of
inlet panels and the inboard firewall assem corrosion resistant steel material that incorpo
blies. The assembly provides support and rates a hook and loop type fastening system.
attachment of the aft swashplate fairing
assembly and contains the through panel 5. AntiTorque Fan Inlet Duct Installation
connection provisions for the engine breather (Ref. Figure 7)
lines, the deck and engine area fire / heat
The fan duct installation is the air inlet
detection system, the engine wire harnesses,
passage which directs air to the inlet of the
and the starter / generator wire harnesses. anti-torque fan, extracts airflow from the fan,
The forward firewall assembly is secured by and directs the extracted flow into the
screw attachments along the left and right tailboom. In addition, this assembly functions
vertical edges. as a secondary structural component that
supports the engine firewalls and serves as the
upper aft section fairing between the left and
The forward firewall assembly panel details, right exhaust ejector cowls. This assembly also
doublers, and stiffening angles are fabricated provides for the attachment of the fan inlet
from titanium alloy sheet. Fastening is by screen assembly.
monel rivets. Fan Inlet Duct Assembly The fan inlet duct
has a large radius opening to enable the
smooth induction into the anti-torque system.
Inboard Firewall Assemblies The left and The duct also forms the upper fairing and
right inboard firewall assemblies extend aft supports the fan inlet screen.
from the forward firewall assembly to FS
The duct is fabricated using multiple plies of
260.00. Along the upper edge, the assembly is graphite/epoxy. In the areas of secondary
bolted to and supports the NOTAR inlet duct attachment of metallic components, local
assembly. Each inboard firewall assembly is barrier plies of fiberglass/epoxy are incorpo
fabricated from titanium alloy sheet. Fasten rated. The forward section of the duct is a
ing is by monel rivets. monolithic laminate. The aft section is a
sandwich panel and incorporates a cocured
Nomex honeycomb core. The stiffening/attach
Aft Firewall Assemblies The left and right ment angles and interconnecting clips are
aft firewall assemblies attach to the aft edges fabricated from aluminum alloy sheet.
of the inboard firewall assemblies, engine deck Middle Inlet Duct Assembly The middle
skins, and deck angles. They extend upward inlet duct assembly slides over the lower
and laterally to the inner surface of the engine flange of the inlet duct assembly, and attaches
cowls. Each assembly contains mounting to the engine deck skins of the upper deck, and
flanges for the aft edge of the engine cowl, the to the forward frame assembly of the fan
secondary exhaust nozzle, and the forward support structure.
edge of the exhaust ejector cowl. All compo The left and right duct assemblies are fabri
nents are fabricated from titanium alloy sheet. cated from graphite/epoxy and barrier plies of
Fastening is by monel rivets. fiberglass/epoxy cocured to any faying surface.
Page 15
53-30-00 Original
NOTAR INLET SCREEN ASSEMBLY
NOTAR INLET DUCT ASSEMBLY
INBOARD FIREWALL ASSEMBLY*
UPPER PORTION
INLET ASSEMBLY*
AFT INLET PANEL*
FORWARD INLET
PANEL*
MIDDLE NOTAR
INLET DUCT ASSEMBLY
LH ENGINE DECK THERMAL INSULATION*
ROOF ASSEMBLY (REFERENCE)

*LH SHOWN, RH OPPOSITE
9G53050
Figure 7. Firewall BuildUp Assembly
Page 16
Original 53-30-00
A. AntiTorque Fan Forward Duct mounting provisions for the upper half of the
Installation fan stator vane assembly, center diffuser, and
the anti-torque fan aft diffuser.
(Ref. Figure 8)
The upper duct is a composite component that
The forward duct installation for the anti- is fabricated with multiple plies of graphite/
torque fan includes the inlet lower duct epoxy. In areas in which attachment of
assembly, drive shaft cover, fan fairing/cent metallic components will occur, barrier plies of
erbody assembly, and wire harness. fiberglass/epoxy are cocured to the faying
Fan Inlet Lower Duct Assembly - The inlet surfaces. The secondary attachment angles
lower duct assembly, combines with the inlet and clips are fabricated from aluminum alloy
and middle duct assemblies to form the air sheet.
passage to the inlet of the anti-torque fan.
Lower Duct Assembly The lower duct
The forward and aft duct components are both assembly is a non-structural removable
fabricated as monolithic laminates. Each component. The lower duct assembly forms the
component utilizes multiple plies of graphite/ lower aft portion of the aft duct assembly. The
epoxy. In addition the aft duct, in areas of lower duct assembly contains the through
secondary attachment of, or to, metallic panel provisions for the electrical harness that
components, barrier plies of fiberglass/epoxy extends through the tailboom to the empen
are cocured to applicable surfaces. nage. The sides of the lower duct assembly are
retained to the sides of the upper duct assem
Fan Drive Shaft Cover - The drive shaft cover bly by means of bolts and secondary attach
covers the underside of the fan drive shaft in ment angles and clips. The aft edge of the
the area beneath the upper deck, and aft to lower duct assembly is retained to the lower
the lower duct assembly. The cover is fabri portion of the interior flange of the tailboom
cated with multiple plies of graphite/epoxy. attach ring assembly by machine screws.
Fan Fairing/Centerbody Assembly The fan The lower duct assembly is fabricated with
fairing/centerbody assembly covers the fan multiple plies of graphite/epoxy. In areas
drive shaft and fairs the center hub of the fan where attachment of metallic components will
assembly on the air inlet side. occur, barrier plies of fiberglass/epoxy are
cocured to the faying surfaces. The secondary
The fan fairing/centerbody assembly consists attachment angles are fabricated from
of a left and right component. Both compo aluminum alloy sheet.
nents are fabricated with multiple plies of
graphite/epoxy. Lower Access Panel Assembly The lower
access panel assembly is a non-structural
B. AntiTorque Fan Aft Duct Assembly and removable component. The lower access panel
Installation assembly combines with the lower duct
(Ref. Figure 8) assembly and forms the lower half of the aft
duct assembly. The lower access panel
The anti-torque fan aft duct assembly directs assembly provides the support of the anti-
the discharge air from the anti-torque fan into torque fan lower stator vanes and lower half of
the tailboom. The aft duct assembly includes the center diffuser. Retention of the panel
the upper duct assembly, lower duct assembly, assembly is by four adjustable latches.
diverter plate assembly, fan stator vane
assemblies, fan center body diffuser assem The lower access panel assembly is fabricated
blies, and the lower access panel assembly. with multiple plies of graphite/epoxy. In areas
where attachment of metallic components will
Upper Duct Assembly The upper duct occur, barrier plies of fiberglass/epoxy are
assembly is a fixed duct that is a secondary cocured to the faying surfaces. Both the upper
structural component that attaches to and and lower components of the aft diffuser are
supports the anti-torque fan support struc fabricated with multiple plies of graphite/
ture. The upper duct assembly contains the epoxy.
Page 17
53-30-00 Original
C. AntiTorque Fan DiffuserStator and Both the upper and lower components of the
Diverter Plate Installation center diffuser are are fabricated as monolithic
laminates. Each composite laminate utilizes
(Ref. Figure 8) multiple plies of graphite/epoxy.
Upper and Lower Aft Diffuser - The
The diffuser-stator and diverter plate
combined components of the aft diffuser
installation includes the installation of the
function to diffuse the air flow exiting the
stator vanes, the upper and lower components
anti-torque fan. The process of diffusion,
of the center diffuser , the upper and lower
involves the gradual increase in flow area and
components of the aft diffuser, the diverter
the conversion of air velocity pressure (dynam
plate assembly, and an electrical access cover.
ic pressure) to static pressure.
Stator Vane Assemblies - The stator vane The upper component of the aft diffuser, is
assemblies function to straighten the air flow attached at the forward end to the center
exiting the anti-torque fan. Nineteen vane diffuser. At the aft end, the upper component
assemblies that are supported by the upper is attached to the diverter plate assembly. The
duct and lower access panel. lower component of the aft diffuser is sup
ported by the upper component and is retained
The stator vane assemblies consist of a vane by bolts and turn lock type fasteners.
with threaded inserts. The vanes are fabri
cated using glass fiber reinforced polypropy Both the upper and lower components of the
lene material that is injection molded. aft diffuser are fabricated as monolithic
laminates. Each laminate utilizes multiple
Upper and Lower Center Diffuser -The plies of graphite/epoxy.
center diffuser consists of an upper and lower Diverter Plate Assembly - The diverter plate
diffuser component that supports the inner assembly is a non-structural component. The
ends of the stator vane assemblies. The upper diverter plate assembly turns the air exiting
center diffuser is attached to the forward end the fan for alignment with the tailboom. The
of the aft diffuser. Attachment of the upper diverter plate also supports and fairs the fan
center diffuser is by the (upper) stator vane control components that are in the fan airflow
assemblies, screws, and the upper duct of the path.
aft duct assembly. Attachment of the lower
center diffuser is by the (lower) stator vane Electrical Access Cover - This access cover
assemblies, screws, and the lower fan access assembly covers the installed electrical
panel. The upper and lower components of the harness, that extends through the tailboom to
center diffuser are aligned by pins that are the empennage. The electrical access cover is
retained in the lower. fabricated from polycarbonate sheet.
Page 18
Original 53-30-00
RH NOTAR FAN
FAIRING/CENTER BODY
LH NOTAR FAN
FAIRING/CENTER BODY
LOWER AFT
NOTAR INLET DUCT
NOTAR DRIVE LOWER FORWARD
SHAFT COVER NOTAR INLET DUCT
STATOR
VANES
ASSEMBLY UPPER AFT
UPPER CENTER DIFFUSER ASSEMBLY
DIFFUSER ASSEMBLY
DIVERTER PLATE
ASSEMBLY
FAN SUPPORT LOWER CENTER LOWER AFT

STRUCTURE (REFERENCE) DIFFUSER ASSEMBLY DIFFUSER ASSEMBLY
9G53107
Figure 8. Forward Duct, Aft Duct, AntiTorque DiffuserStator, and Diverter Plate Installation
Page 19
53-30-00 Original
D. AntiTorque Fan Support Structure Aft Frame - The aft frame is a primary
structural component that provides the aft
structural interface and support for the fan
(Ref. Figure 9) installation. The aft frame also attaches the
forward end of the fan aft duct assembly. The
aft frame assembly is fabricated from alumi
The major components included in this num alloy sheet.
support structure are the fan support ring,
forward frame assembly, aft frame, left and Duct Inner Skins The left and right duct
inner skins are primary structural components
right duct inner skins, upper and lower
that provide the attachment and support for
intercostals, and left and right WL 159.00
the felt-metal tip seal for the fan assembly.
intercostals, and lower skin web.
The left and right inner skins form a circular
ring that is attached to both the forward frame
Secondary components installed within this assembly and the aft frame. The duct inner
structure include doubler plates and angles, skins are fabricated from aluminum alloy
stiffeners, channels, and standard hardware. sheet.
Intercostals The upper, lower, and left and
Fan Support Ring - The fan support ring is right WL 159.00 intercostals are secondary
machined from aluminum alloy stock. The fan structural components. The are fabricated
support ring contains a peripheral flange that from aluminum alloy sheet.
attaches onto the forward frame assembly. E. Tailboom Attachment Ring Assembly
Three arms provide the attachment for the fan
fairing/centerbody, the support for the fan (Ref. Figure 9)
bearing housing, and the fan support bearing
The tailboom attachment ring assembly is a
housing.
primary structural component that attaches
the tailboom to the aft section of the fuselage.
The inner flange of the ring assembly provides
Forward Frame Assembly - The forward
for attachment of the aft flanges of the upper
frame assembly is a primary structural
and lower anti-torque fan duct assemblies.
component that provides for installation and
attachment of the fan support ring. This The tailboom attachment ring assembly
component also provides the forward structur consists of the tailboom attachment ring,
al interface and support for the anti-torque nutplates, two close tolerance bolts and bolt
fan installation. The forward frame assembly retainers. The tailboom attachment ring is
is fabricated from aluminum alloy sheet. machined from aluminum alloy stock.
Page 20
Original 53-30-00
WL 159.00 INTERCOSTALS
FWD FRAME UPPER
SUPPORT RING ASSEMBLY INTERCOSTAL
UPPER DUCT ASSEMBLY
RH INNER SKIN DUCT
LOWER DUCT
ASSEMBLY
LOWER ACCESS
PANEL ASSEMBLY
LH INNER SKIN
LOWER INTERCOSTAL DUCT
AFT FRAME
LOWER SKIN WEB
ANTITORQUE FAN SUPPORT STRUCTURE
TAILBOOM ATTACHMENT
RING ASSEMBLY
9G53033
Figure 9. AntiTorque Fan Support Structure, Aft Duct Assembly, and Tailboom Attachment
Ring Assembly
Page 21
53-30-00 Original
RH REAR FUSELAGE
SHELL ASSEMBLY
LH REAR FUSELAGE
SHELL ASSEMBLY
CUTOUT FOR UPPER WORK PLATFORM
CUTOUT FOR LOWER WORK PLATFORM FOOTSTEP

(LH SHOWN, RH OPPOSITE) (LH SHOWN, RH OPPOSITE)
9G53049
Figure 10. Rear Fuselage Shell Assemblies

F. Rear Fuselage Shell Assemblies step, step plate, foot step support angle, and
the work platforms provide for access to the
(Ref. Figure 2 and Figure 10) upper deck
The rear fuselage shell assemblies are primary
structural components. The left and right rear The rear fuselage shell assemblies are
fuselage shell assemblies are attached to the fabricated utilizing multiple plies of graphite/
aft cabin door frame, the FS 230.50 frame, roof epoxy and fiberglass/epoxy cocured with a
structure assemblies, and the tailboom attach honeycomb core. A ply of Astrostrik
is
ring assembly. cocured to the exterior surface of the panel.
Around the periphery of each panel, in the
The rear fuselage shell assemblies incorporate areas of secondary attachment, and in the
a secondarily bonded foot step assembly areas of the cutouts for the work platforms,
located aft and below the cutouts for the the core is tapered and the panel transitions to
installation of the work platforms. The foot a monolithic laminate.
Page 22
Original 53-30-00
SPLICE PLATE
REAR FUSELAGE
SHELL
(REF)
UPPER BAG
GAGE
DOOR FRAME
UPPER STRIKER
PLATE
SIDE STRIKER
RH KICK STRIP
LOWER STRIKER
PLATE
CENTER KICK STRIP
LH KICK STRIP
LOWER BAGGAGE
DOOR FRAME
9G53037
Figure 11. Baggage Door Frame Installation

6. Baggage Door Frame Installation B. Splice Plate
(Ref. Figure 11) The splice plate is a secondary structural
component and is used to secure the butt joint
The baggage door frame installation installs between the left and right rear fuselage shell
upper and lower baggage door frame compo
assemblies in the area between the upper
nents. These frames are secondary structural
baggage door frame and the tailboom attach
components and reinforce the baggage door
ment ring. Attachment of this component is by
opening formed by the left and right rear
rivets. The splice plate is fabricated from
fuselage shells and aft edge of the boat tail aluminum alloy sheet.
assembly. All components within this installa
tion are installed using rivets.
C. Baggage Door Kick Strips
A. Baggage Door Frames
The baggage door frame installation installs
The baggage door frame installation installs kick strips along the lower portion of the
upper and lower baggage door frame compo baggage door opening. The kick strip consists
nents. These frames are secondary structural of left, center, and right component that install
components and reinforce the baggage door over the composite lower frame and protect the
opening formed by the left and right rear frame from potential impact damage. These
fuselage shells and aft edge of the boat tail components are installed with screws. These
assembly. All components within this installa components are fabricated from aluminum
tion are installed using rivets. alloy sheet.
Page 23
53-30-00 Original
D. Striker Plates B. Forward Fairing Support Assemblies

The baggage door installation installs three The left and right forward fairing support
striker plates; an upper, a lower, and side assemblies, attach to and support the forward
striker plate. Each striker plate is installed and aft swashplate fairing assemblies. Door
with screws. The striker plates are fabricated latching strikers/receptacles are attached at
from corrosion resistant steel sheet. forward and transmission access door interface
locations. In addition, the support assemblies
7. Forward Fairings and Doors Installation provide the aft and forward seal lands for the
(Ref. Figure 12) forward and transmission access doors.
The forward fairings and doors installation (NACA CONFIG) On aircraft with NACA
includes the forward and aft swashplate engine inlets installed, the forward fairing
fairing assemblies, the left and right forward support assemblies also support the forward
access door assemblies, the left and right end of the NACA inlet duct.
transmission access door assemblies, hinge
and door latch hardware, and the left and Each forward fairing support assembly
right forward fairing support assemblies. consists of metallic supports, frames, doublers,
Components within this installation, although intercostals, angles, a 4-mesh wire oil cooler
not considered structural, do transfer and inlet screen, and a composite oil cooler inlet
support aerodynamic air loads generated by duct frame. All metallic components are
flight or by main rotor down wash. fabricated from aluminum alloy sheet. The
4-mesh wire cloth oil cooler inlet screen is
A. Swashplate Fairing Assemblies fabricated from 0.032-0.035 in. (0.81-0.89
mm) diameter corrosion resistant steel wire.
The forward and aft swashplate fairing The oil cooler inlet duct frame is fabricated as
assemblies join to each other on each side. The a cocured multiple ply monolithic laminate
forward end of the combined assembly is incorporating graphite/epoxy and fiberglass/
attached to the FS 155.50 fuselage bulkhead. epoxy.
The aft end of the combined assembly is
attached to the forward firewall assembly and C. Fixed Panel Assemblies
the left and right inlet panels. The center of
the combined assembly is attached to the The left and right fixed panel assemblies are
forward fairing support assemblies. All removable filler panels that are installed
attachments to supporting structure or between the lower aft edge of the transmission
components, as well as at the joint to each access door and the lower edge of the forward
other, is by screws and bolts. inlet panel. The fixed panel assemblies
complete the seal land and incorporate the aft
The forward and aft swashplate fairing mounting provisions for the transmission
assemblies are constructed of multiple plies of access doors. Attachment of the panel assem
graphite/epoxy cocured with Nomex honey blies is by screws and bolts.
comb core. Around the periphery of each panel
assembly, and in the areas of secondary The fixed panel assemblies are built-up
attachment, the core tapers and the sandwich assemblies. Each assembly consists of a panel,
panel transitions to form monolithic laminate frame, and spacer, as well as standard
flanges that incorporate additional reinforce hardware. All components are fabricated from
ment plies of graphite/epoxy. aluminum alloy sheet.
Page 24
Original 53-30-00
D. Forward Access Door Assemblies (EARLY CONFIG) - Each access door assem
bly is hinge mounted to the outboard edges of
The left and right forward access doors provide the aft swashplate fairing assembly and is
access to the forward area of the upper deck. retained in the closed position by means of
Each access door assembly is hinge mounted to latches and or quarter turn fasteners.
outboard edges of the forward swashplate
fairing assembly and is retained in the closed The transmission access door assemblies are
position by means of latches and or quarter fabricated of graphite/epoxy skins cocured with
turn fasteners. In the opened position, each a Nomex honeycomb core. Around the periph
door assembly is supported by a locking strut ery of the panel assembly, and in the areas of
assembly. hinge and latch attachment, the core is
tapered and the panel transitions to form
The forward and transmission access door monolithic laminate flanges which incorporate
assemblies are fabricated of graphite/epoxy additional plies of graphite/epoxy. In the areas
cocured with a Nomex honeycomb core. of secondary attachment of metallic compo
Around the periphery of the panel assembly, nents, barrier plies of fiberglass/epoxy are
and in the areas of hinge attachment, the core cocured to the faying surfaces. In the opened
is tapered and the panel transitions to form position, each door assembly is supported by a
monolithic laminate flanges which incorporate locking strut assembly.
additional reinforcement plies of graphite/
epoxy. In the areas of secondary attachment of (NACA CONFIG) The left and right transmis
metallic components, barrier plies of fiber sion access doors are separated into two door
glass/epoxy are cocured to the faying surfaces. assemblies, one above the NACA inlet and one
panel below the NACA inlet. The upper door
The door seals installed around the periphery assembly is hinge mounted to the outboard
of each door assembly are closed cell silicone edges of the aft swashplate fairing assembly
material with a self-adhering backing. and is retained in the closed position by
E. Transmission Access Door Assemblies quarter turn fasteners. The lower door
assembly is retained by quarter turn fasteners
The left and right transmission access doors only.
provide access to the aft area of the upper
deck. The transmission access door and panel
assemblies are fabricated of graphite/epoxy. In
The door seals installed around the periphery the areas of secondary attachment of metallic
of each door assembly are closed cell silicone components, barrier plies of fiberglass/epoxy
material with a self-adhering backing. are cocured to the faying surfaces.
Page 25
53-30-00 Original
AFT SWASHPLATE FAIRING ASSEMBLY
OIL COOLER EXHAUST AIR SCREEN*

NOTE
OIL DIPSTICK HANDHOLD
FORWARD SWASHPLATE TRANSMISSION ACCESS

FAIRING ASSEMBLY DOOR ASSEMBLY*
FIXED PANEL ASSEMBLY*
OIL COOLER AIR INLET SCREEN*
FORWARD ACCESS DOOR ASSEMBLY*
900 CONFIG
*LH SHOWN, RH OPPOSITE
NOTE: 902 CONFIG FMU VAPOR

SHROUD VENT IS INCORPORATED
INBOARD OF OIL COOLER EXHAUST
NACA CONFIG
9G53104A
Figure 12. Forward Fairings and Doors
Page 26
Original 53-30-00
8. Aft Cowling and Fairing Installation The insulation blanket provides fire and heat
protection for the composite panel. The
(Ref. Figure 13) insulation blanket is a molded assembly that
The aft cowling installation includes the is fabricated with special fire proof fabric inner
installation of the left and right engine cowl and outer skins separated by heat insulating
assemblies, the left and right exhaust ejector filler material. Installation of the blanket onto
cowls, the left and right deck angle seals, and the panel is by a silicone type adhesive.
the tailboom upper fairing assembly. Compo B. Exhaust Ejector Cowl Assemblies
nents installed within this installation,
although not considered structural, do transfer The left and right exhaust ejector cowl
and support aerodynamic air loads generated assemblies cover the secondary exhaust
by flight or by main rotor down wash. ejector. Attachment of each cowl assembly is
by means of screws and nutplates. Each
A. Engine Cowl Assemblies exhaust ejector cowl assembly includes upper
Each engine cowl assembly includes an engine and lower cowl panels, a closeout panel, and
cowl panel, upper edge stiffeners, (air vent) standard hardware. The upper, lower, and
screens and screen frames, insulation blanket, closeout panels are secondarily bonded and
and standard hardware. The left and right rivet together to form the completed cowl
engine cowl assemblies combine with the inlet assembly.
panel, inboard and aft firewall components,
The upper and lower panels of each assembly
deck skin components, and engine deck
is fabricated of graphite/epoxy that incorpo
thermal insulation, to form the fire proof
rates stiffening ribs of cocured syntactic foam
enclosure that contains the engine and the core, with local barrier plies of fiberglass/epoxy
primary exhaust nozzle. Each cowl assembly is
in areas of metallic component interface.
attached by screws and nutplates.
The closeout panel, located at the aft, outboard
The engine cowl panel is composite and is
corner of each cowl assembly, is fabricated as a
fabricated as a monolithic laminate, that
monolithic laminate that utilizes multiple plies
incorporates stiffening ribs of cocured syntactic
of graphite/epoxy.
foam core material. The panel is fabrication of
graphite/epoxy with local barrier plies of C. Tailboom Upper Fairing Assembly
fiberglass/epoxy in areas of metallic compo
nent interface. A forward and an aft edge The tailboom upper fairing assembly closes out
stiffener are fabricated from aluminum alloy the aft end of the upper deck fairings installa
sheet. tion between the exhaust ejector cowl assem
blies. The fairing assembly is attached by
Two screens are contained within each cowl screws and mating nutplates.
assembly. The screens are fabricated from 4
mesh 0.032-0.035 in. (0.81-0.89 mm) The tailboom upper fairing assembly consists
diameter corrosion resistant steel wire. The of a fairing panel and edge seals. The fairing
screen frames are fabricated from titanium panel is fabricated using multiple plies of
alloy sheet. The screens and screen frames are graphite/epoxy. The edge seals are closed cell
retained by rivets. silicone material with a self-adhering backing.
Page 27
53-30-00 Original
TAILBOOM UPPER FAIRING ASSEMBLY
EXHAUST EJECTOR COWL ASSEMBLY

ENGINE COWL ASSEMBLY

FIREWALL BUILDUP ASSEMBLY (LH SHOWN, RH OPPOSITE)
AND INSTALLATION (REFERENCE)
9G53105
Figure 13. Aft Engine Cowling
Page 28
Original 53-30-00

1. Forward Access Door Assembly (L155, (3). Disengage locking ends of hinge pins (3)
R155) and Transmission Access Door and remove pins and access door (1 or
Assembly (L210, R210) 2) from fairing (4 or 5).
A. Access Door Assembly Removal B. Access Door Assembly Installation

(Ref. Figure 401)
(Ref. Figure 401)
NOTE: Installation of forward access doors,
NOTE: Removal of forward access doors, L155 L155 and R155, and transmission access
and R155, and transmission access doors, doors, L210 and R210 assemblies are typi
L210 and R210 assemblies are typical. cal.
Subsequent to access door re (1). Position access door assembly (1 or 2) in
CAUTION moval wrap door in protective appropriate location beneath fairing (4
covering and store in safe location to avoid or 5) and align hinge halves.
damage to composite door skins.
(2). Install hinge pins (3) and ensure
(1). Open access door assembly (1 or 2) to locking ends are properly engaged.
gain access to door strut (Ref. Section (3). Attach access door strut to access door
06-00-00). bracket (Ref. Section 53-30-00).
(2). Disconnect strut attachment to access (4). Close access door and check for proper
door bracket (Ref. Section 53-30-00). operation of door.
Page 401
53-30-00 Original
2
4
1
900 CONFIG
NACA CONFIG
9G53-091A
1. FORWARD ACCESS DOOR ASSEMBLY (L155, R155) 3. HINGE PIN

2. TRANSMISSION ACCESS DOOR ASSEMBLY (L210, 4. SWASHPLATE FORWARD FAIRING ASSEMBLY (T155)
R210) 5. SWASHPLATE AFT FAIRING ASSEMBLY (T220)
Figure 401. Access Door
2. Access Door Strut (b). Pull end fitting socket away from ball
end of ball screw (8) on bracket.
A. Access Door Strut Removal
(3). Remove access door strut.
(Ref. Figure 402)
NOTE: B. Access Door Strut Installation
Removal of struts for forward access (Ref. Figure 402)
doors, L155 and R155, and transmission
access doors, L210 and R210 assemblies NOTE:
are typical.
Installation of struts for forward access
(NACA CONFIG) Door struts are not doors, L155 and R155, and transmission
installed on L210 and R210. access doors, L210 and R210 assemblies
are typical.
(1). Open access door to gain access to door
strut (2) (Ref. Section 53-30-00). (NACA CONFIG) Door struts are not
installed on L210 and R210.
(2). Disconnect upper attachment to
bracket (3) on access door and lower Two different access door strut lengths
attachment to bracket on swashplate are utilized. Nominal closed length of the
fairing assembly. strut for forward access doors, L155 and
R155, is 14.60-in. Nominal closed length
(a). Slide case (9) of quick-disconnect ball of the strut for transmission access doors,
joint end fitting along axis of strut. L210 and R210, is 18.80-in.
Page 402
Original 53-30-00
(1). Extend access door strut (2) to the fully (3). Remove screws (4) and washers (5), and
locked position. remove strut bracket.
(2). Secure end fittings of strut to bracket (4). Remove nut (7), washers (6), and ball
on swashplate fairing support assembly screw (8) from bracket.
and bracket (3) on inner surface of
access door. D. Access Door Strut Bracket Installation
(Ref. Figure 402)
(a). Ensure strut is positioned with
extended rod end fitting at bracket of NOTE: Installation of access door strut brack
swashplate fairing support. ets is typical.
(b). Slide case (9) of quick-disconnect ball (1). Install ball screw (8) on strut bracket
joint end fitting along axis of strut. (3) using washers (6) and nut (7).
Torque nut.
(c). Position end fitting socket over ball
end of ball screw (8) and release case. (2). Position strut bracket over molded-in
Ensure case is completely seated over inserts on inner surface of access door
ball end of ball screw. panel (1).
C. Access Door Strut Bracket Removal (a). On forward access doors, L155 and
R155, ensure ball end of ball screw is
(Ref. Figure 402) positioned aft.
NOTE: Removal of access door strut brackets is (b). On transmission access doors, L210
typical. and R210, ensure ball end of ball
screw is positioned forward.
(1). Gain access to door strut (2) and strut
bracket (3). (3). Install screws (4) and washers (5).
Torque screws.
(2). Disconnect door strut attachment to
strut bracket (Ref. Section 53-30-00). (4). Connect door strut (2) to ball screw (8).
Page 403
53-30-00 Original
1 2
10
9
3 LOOKING INBOARD
LEFT SIDE
VIEW ROTATED
4 (2 PL) 2
5 (2 PL)
8
6 VIEW ROTATED
7 9G53-087A
1. DOOR PANEL 6. WASHER
2. DOOR STRUT 7. NUT
3. STRUT BRACKET 8. BALL SCREW
4. SCREW 9. CASE
5. WASHER 10. LOCK RELEASE COLLAR
Figure 402. Access Door Strut and Strut Bracket
Page 404
Original 53-30-00
3. Access Door Striker (EARLY CONFIG) B. Access Door Striker Installation

A. Access Door Striker Removal
(Ref. Figure 403)
(Ref. Figure 403)
NOTE: Removal of latch strikers for forward NOTE: Installation of latch strikers for forward
access doors, L155 and R155, and transmis
access doors, L155 and R155, and transmis
sion access doors, L210 and R210 assem
sion access doors, L210 and R210 assem
blies are typical.
blies are typical.
(1). Open access door (1) and secure with (1). Position striker plate (2, 6, or 10) onto
access door strut (Ref. Section striker adjustment plate (3, 7, or 11)
06-00-00). using position noted prior to removal.
Ensure serrations are fully engaged.
(2). Remove bolts (4, 8, or 12) and washers
(5, 9, or 13).
(2). Position striker plate and striker
(3). Remove striker plate (2, 6, or 10) and adjustment plate against mounting
striker adjustment plate (3, 7, or 11). bracket in appropriate location as noted
prior to removal. Install bolts (4, 8, or
(a). Prior to removal note and mark 12) and washers (5, 9, or 13). Torque
position of striker plate to striker bolts.
adjustment plate.
(b). Retain striker plate, striker adjust (3). Close access door and check for proper
ment plate, and mounting hardware latch operation. Adjust access door
in sets marked with the installed latch and/or access door striker if
location. necessary (Ref. Section 53-30-00).
Page 405
53-30-00 Original
10
LEFT SIDE, LOOKING INBOARD 12 (2 PL)

13 (2 PL)
11
3 8 (2 PL) 6
9 (2 PL)
4 (2 PL) 7
5 (2 PL)
LOOKING AFT
LOOKING FWD LOOKING AFT 9G53-064
1. FORWARD ACCESS DOOR (L155, R155) 8. BOLT
2. STRIKER PLATE 9. WASHER
3. STRIKER ADJUSTMENT PLATE 10. STRIKER PLATE
4. BOLT 11. STRIKER ADJUSTMENT PLATE
5. WASHER 12. BOLT
7. STRIKER ADJUSTMENT PLATE
Figure 403. Access Door Strikers (EARLY CONFIG)
Page 406
Original 53-30-00
4. Forward Fairing Support Assembly B. Forward Fairing Support Assembly

Installation
A. Forward Fairing Support Assembly
NOTE: Installation of the left and right for
(Ref. Figure 404) ward fairing support assemblies is typical.
NOTE: Removal of the left and right forward (1). Position forward fairing support
fairing support assemblies is typical. assembly (1) on upper deck outboard of
oil cooler blower air inlet duct.
(1). Remove forward access doors, L155 and (2). Slide support assembly inboard ensur
R155, and transmission access doors, ing oil cooler blower air inlet duct
L210 and R210 as applicable (Ref. engages duct frame of support assem
Section 53-30-00). bly. Ensure seal (6) is properly seated
between air inlet duct and duct frame
(2). Remove access door struts (Ref. Section around entire periphery.
53-30-00).
(3). Install bolts (2) and washers (3) in
(3). (NACA CONFIG) Remove NACA inlet support assembly (1). Torque bolts.
duct (Ref. Section 71-60-00). (4). Install bolts (4) and washers (5) in
support assembly to upper deck. Torque
(4). Remove bolts (2) and washers (3) from bolts.
support assembly (1) to forward
swashplate fairing assembly. (5). (NACA CONFIG) Install NACA inlet
duct (Ref. Section 71-60-00).
(5). Remove bolts (4) and washers (5) from (6). Install forward access doors, L155 and
support assembly to upper deck. R155, and transmission access doors,
L210 and R210 as applicable (Ref.
(6). Remove support assembly by sliding Section 53-30-00).
assembly outboard insuring duct frame
of support assembly is clear of oil cooler (7). Install access door struts (Ref. Section
air inlet duct and remove. 53-30-00).
Page 407
53-30-00 Original
2 (2 PL)
3 (2 PL)
4 4
5 5
EARLY CONFIG
CURRENT CONFIG 9G53-083A
1. SUPPORT ASSEMBLY 4. BOLT

2. BOLT 5. WASHER
3. WASHER 6. SEAL
Figure 404. Forward Fairing Support Assembly

5. Fixed Panel Assembly NOTE: Installation left and right fixed panel
assemblies is typical.
A. Fixed Panel Assembly Removal
(1). Position fixed panel assembly (4) at the
(Ref. Figure 405) corner of the engine air inlet (7) and
upper deck angle (6).
NOTE: Removal of left and right fixed panel as
semblies is typical. (a). Ensure the flange of the engine air
(1). Open transmission access door, L210 or inlet (7) nests between the upper aft
R210 as applicable, and secure (Ref. corner of the panel frame (8) and the
Section 06-00-00). panel (4).
(2). Remove screws (2) and washers (3) (b). Ensure the lower edge of the panel
which secure panel (4) to fixed panel (4) nests against the outboard
bracket (5), deck angle (6) and engine surface of the deck angle (6).
air inlet assembly (7). Ensure upper aft
corner of panel assembly frame (8) (2). Install screws (2) and washers (3).
clears flange of inlet assembly as panel Torque screws.
assembly is removed.
(3). Close transmission access door, L210 or
B. Fixed Panel Assembly Installation R210 as applicable, and check for
proper operation of access door (Ref.
Page 408
Original 53-30-00
9 (4 PL)
10 (4 PL) 5
6 3 (4 PL)
2 (4 PL)
8
9G53-066
1. STRIKER 6. DECK ANGLE

2. SCREW 7. ENGINE AIR INLET ASSEMBLY
3. WASHER 8. PANEL ASSEMBLY FRAME
4. FIXED PANEL ASSEMBLY 9. BOLT
5. FIXED PANEL BRACKET 10. WASHER
Figure 405. Fixed Panel Assembly

6. Fixed Panel Bracket Assembly B. Fixed Panel Bracket Assembly
Installation
A. Fixed Panel Bracket Assembly Removal
(Ref. Figure 405)
(Ref. Figure 405)
NOTE: Installation of left and right fixed panel
bracket assemblies is typical.
NOTE: Removal of left and right fixed panel
bracket assemblies is typical. (1). Position the fixed panel bracket
assembly (5) immediately inboard of
(1). (EARLY CONFIG) Open transmission the fixed panel assembly (4).
access door, L210 or R210 as applicable,
and secure with door strut (Ref. Section (2). Install bolts (9) and washers (10).
06-00-00). Torque bolts.
(2). (NACA CONFIG) Open transmission (3). Install screw (2) and washer (3) at the
access door, L210 or R210 as applicable lower, forward corner of fixed panel
(Ref. Section 06-00-00). assembly (4). Torque screw.
(4). (EARLY CONFIG) Install striker (1)
(3). (EARLY CONFIG) Remove striker (1)
for aft latch of transmission access door
for aft latch of transmission access door
(5). Close transmission access door, L210 or
(4). Remove screw (2) and washer (3) from R210 as applicable (Ref Section
lower, forward corner or fixed panel 06-00-00).
assembly (4).
(6). (EARLY CONFIG) Check for proper
(5). Remove bolts (9) and washers (10) operation of aft latch. Adjust access
securing fixed panel bracket (5) to door latch and/or striker if necessary
upper deck. (Ref. Section 53-30-00).
Page 409
53-30-00 Original
7. Oil Cooler Air Outlet Screen Assembly (b). Install screws with wet sealing
compound (C211), (C212), (C213), or
A. Oil Cooler Air Outlet Screen Assembly (C214) or primer (C309) and torque
Removal screws.
(Ref. Figure 406) 8. Swashplate Forward Fairing Assembly
(T155)
NOTE: Removal of left and right oil cooler air
outlet screen assemblies is typical. A. Swashplate Forward Fairing Assembly
Removal
(1). Remove screws and washers securing
oil cooler screen (1) to swashplate aft (Ref. Figure 406)
fairing (3).
(1). Remove forward access doors, L155 and
(2). Remove oil cooler air outlet screen R155, and transmission access doors,
assembly. L210 and R210 assemblies (Ref. Section
53-30-00).
B. Oil Cooler Air Outlet Screen Assembly
Installation (2). Disconnect vent system inlet to separa
tor flexible duct (8) by removing band
(Ref. Figure 406) clamp at bottom of duct (Ref. Section
21-20-00).
Consumable Materials (3). Fairing Assembly with Generator
(Ref. CSPSPM) Cooling Modification - Detach
Item Nomenclature cooling ducts from swashplate fairing
C211 Sealing Compound, Corrosion Inhibitive (Ref. Section 71-60-00, Cooling Duct
Removal).
C213 Sealing Compound, Corrosion Inhibitive (4). Remove screws and washers securing
C214 Sealing Compound, Corrosion Inhibitive forward edge of swashplate forward
fairing assembly (2).
C309 Primer
(5). Remove screws, washers, and nuts at
joint to swashplate aft fairing assembly.
NOTE: Installation of left and right oil cooler
air outlet screen assemblies is typical. (6). Remove torq-set bolts (4), washers (5),
and nuts (6) securing splice angle (7) to
(1). Position oil cooler air outlet screen outboard flanges of fairing assembly.
assembly (1) over outlet on swashplate
aft fairing assembly (3). (7). Remove screws and washers securing
upper end of forward fairing support
Sealing Compound (C211) assembly to outboard flanges of fairing
assembly.
Ensure forward end of aft
CAUTION swashplate fairing assembly is
supported prior to complete removal of
Primer (C309) hardware.
(8). Remove fairing assembly by moving
assembly forward and up.
(a). Ensure flanges at joints to swash
(2). Install screws and washers. plate aft fairing assembly are com
pletely disengaged.
(a). Ensure screws properly engage
nutplates on flange of cooling ex (b). Ensure outboard flanges are clear of
haust duct. upper ends of support assemblies.
Page 410
(9). Remove hinges if applicable (Ref assembly. Install screws with wet
Section 53-30-00). sealing compound (C211), (C212),
(C213), or (C214) or primer (C309) and
B. Swashplate Forward Fairing Assembly
torque screws.
Installation
(Ref. Figure 406)
(4). Install torq-set bolts (4), washers (5)
and nuts (6) to secure flanges of fairing
(Ref. CSPSPM) assembly to splice angle (7). Install
Item Nomenclature bolts with wet sealing compound
(C211), (C212), (C213), or (C214) or
primer (C309) and torque nuts.
C214 Sealing Compound, Corrosion Inhibitive (5). Install screws, washers, and nuts at
C309 Primer joint to aft swashplate fairing assembly.
Install screws with wet sealing com
pound (C211), (C212), (C213), or (C214)
(1). Install or replace hinges if applicable
or primer (C309) and torque nuts.
(2). Position swashplate forward fairing
assembly (2) over swashplate and mast (6). Install screws and washers at forward
support assemblies with front edge on edge of fairing assembly. Install screws
flange of FS 155 frame. with wet sealing compound (C211),
(C212), (C213), or (C214) or primer
(a). Ensure aft flanges of fairing assem
(C309) and torque screws.
bly nest over mating flanges of
swashplate aft assembly.
(b). Ensure outboard flanges of fairing (7). Fairing Assembly with Generator
assembly are inboard of upper ends Cooling Modification - Attach
of support assemblies and that cooling ducts to swashplate fairing (Ref.
flanges of splice angles are inboard of Section 71-60-00, Cooling Duct
flanges. Installation).
(8). Connect vent system inlet to separator
flexible duct (8) (Ref. Section
21-20-00).
Primer (C309)
(9). Install forward access doors, L155 and
R155, and transmission access doors,
L210 and R210 assemblies (Ref. Section
53-30-00).
(3). Install screws and washers to secure
support assemblies to flanges of fairing
Page 411
4 (4 PL)
5 (4 PL)
6 (4 PL)
7 1
2
3
8
LEFT SIDE, LOOKING INBOARD 90007610100-101-c-f

9G53-069A
1. OIL COOLER AIR OUTLET SCREEN (900 CONFIG) 4. TORQSET BOLT

OIL COOLER AIR OUTLET AND ENGINE FMU VAPOR 5. WASHER
SHROUD OUTLET SCREEN (902 CONFIG) 6. NUT
2. SWASHPLATE FORWARD FAIRING ASSEMBLY (T155) 7. SPLICE ANGLE
3. SWASHPLATE AFT FAIRING ASSEMBLY (T220) 8. FLEXIBLE DUCT
Figure 406. Swashplate Forward and Aft Fairings
9. Swashplate Aft Fairing Assembly (T220) (4). Remove screws, washers, and nuts at
joint to swashplate forward fairing
A. Swashplate Aft Fairing Assembly assembly.
Removal
(5). Remove torq-set bolts (4), washers (5)
and nuts (6) securing flanges of fairing
(Ref. Figure 406) assembly to splice angle (7).
(1). Remove forward access doors, L155 and (6). Remove fairing assembly by lifting aft
R155, and transmission access doors, edge up and moving assembly aft and
L210 and R210 assemblies (Ref. Section up.
53-30-00).
(a). Ensure flanges at joints to swash
(2). Remove screws and washer from left plate forward fairing assembly are
and right oil cooler air outlet screens completely disengaged.
(1).
(b). Ensure fairing assembly is clear of oil
(3). Remove screws and washers securing cooler blower exhaust ducts.
aft edge of swashplate aft fairing
assembly (3) to firewall and engine air (7). Remove hinges if applicable (Ref
inlet assemblies. Section 53-30-00).
Page 412
Revision 6 53-30-00
(8). Remove oil dipstick handhold assem Install bolts with wet sealing compound
blies if applicable (Ref. Section (C211), (C212), (C213), or (C214) or
53-30-00). primer (C309). Torque nuts.
B. Swashplate Aft Fairing Assembly (5). Install screws, washers, and nuts at
Installation joint to forward swashplate fairing
assembly. Install screws with wet
(Ref. Figure 406) sealing compound (C211), (C212),
(C213), or (C214) or primer (C309).
Torque screws.
(Ref. CSPSPM) (6). Install screws, and washers on aft edge
Item Nomenclature of assembly. Install screws with wet
C211 Sealing Compound, Corrosion Inhibitive sealing compound (C211), (C212),
C212 Sealing Compound, Corrosion Inhibitive (C213), or (C214) or primer (C309).
Torque screws.
C214 Sealing Compound, Corrosion Inhibitive (7). Install left and right oil cooler air outlet
C309 Primer screen assemblies (1) with screws and
washers. Torque screws.
(1). Install or replace hinges if applicable (8). Install forward access doors, L155 and
(Ref. Section 53-30-00). R155, and transmission access doors,
L210 and R210 assemblies (Ref. Section
(2). Install or replace oil dipstick handholds 53-30-00).
if applicable (Ref. Section 53-30-00).
10. Engine Cowl Assembly (L260, R260)
(3). Position swashplate aft fairing assem
bly (3) over swashplate and mast A. Engine Cowl Assembly Removal
support with aft edge on flanges of
firewall and engine air inlet assemblies. (Ref. Figure 407)
(a). Ensure forward flanges of fairing NOTE: Removal of engine cowl L260 and R260
assembly nest under mating flanges assemblies is typical.
of swashplate forward fairing assem
bly. (1). Remove screws (1) and washers (2)
which secure engine cowl assembly to
(b). Ensure outboard flanges nest over airframe.
splice angles (7).
(2). Remove engine cowl assembly (3).
B. Engine Cowl Assembly Installation
(Ref. Figure 407)
Primer (C309) NOTE: Installation of engine cowl L260 and

R260 assemblies is typical.
(1). Position engine cowl assembly (3) over

engine and align screw holes with nut
plates in airframe.
(4). Install torq-set bolts (4), washers (5)
and nuts (6) to secure outboard flanges (2). Install screws (1) and washers (2).
of fairing assembly to splice angle (7). Torque screws.
Page 413
53-30-00 Original
1
2
9G53-093A
1. SCREW 3. ENGINE COWLING ASSEMBLY (L260)

2. WASHER
Figure 407. Engine Cowl Assembly
11. Exhaust Ejector Cowl Assembly (L270, B. Exhaust Ejector Cowl Assembly
R270) Installation
A. Exhaust Ejector Cowl Assembly Removal (Ref. Figure 408)
(Ref. Figure 408) NOTE: Installation of exhaust ejector cowl
NOTE: Removal of exhaust ejector cowl L270 L270 and R270 assemblies is typical.
and R270 assemblies is typical.
(1). Position exhaust ejector cowl assembly
(1). Remove screws (1) and washers (2) (6) over ejector assembly.
which secure tailboom upper fairing
assembly (3) to airframe. (2). Install screws (4) and washers (5) along
top, forward, and lower edges of cowl
(2). Remove screws (4) and washers (5) (6). Torque screws. Leave the two aft
which secure lower, forward, and upper locations on the lower edge vacant.
edges of exhaust ejector cowl assembly
(6) and remove assembly. Ensure (3). Install tailboom upper fairing assembly
assembly is clear of ejector outlet prior (3) with screws (1) and washers (2).
to complete removal. Torque screws.
Page 414
Original 53-30-00
1
2
3
4
5
9G53-092A
1. SCREW 4. SCREW
2. WASHER 5. WASHER
3. TAILBOOM UPPER FAIRING ASSEMBLY (T292) 6. EXHAUST EJECTOR COWL ASSEMBLY (L270)
Figure 408. Exhaust Ejector Cowl Assembly
12. Engine Upper Inlet Assembly firewall assembly (4). Remove inlet
assembly.
A. Engine Upper Inlet Assembly Removal
B. Engine Upper Inlet Assembly Installation
(Ref. Figure 409)
(Ref. Figure 409)
NOTE: Removal of left and right engine upper NOTE: Installation of left and right engine up
inlet assemblies is typical. per inlet assemblies is typical.
(1). Remove fixed panel assembly (Ref (1). Secure upper inlet assembly (3) to
Section 53-30-00). firewall assembly (4) with bolts (1) and
washers (2). Torque bolts.
(2). Remove engine cowl assembly L260 or
R260 (Ref. Section 53-30-00). (2). Install engine firewall to plenum seals
(3). (NACA CONFIG) - Remove NACA
inlet duct (Ref. Section 71-60-00). (3). Install engine wash system (Ref.
Section 71-60-00).
(4). Remove inlet screen or inlet particle
separator (Ref. Section 71-60-00). (4). (NACA CONFIG) - Install NACA inlet
duct (Ref. Section 71-60-00).
(5). Remove engine wash system (Ref. (5). Install inlet screen or inlet particle
Section 71-60-00). separator (Ref. Section 71-60-00).
(6). Remove engine firewall to plenum seals (6). Install engine cowl assembly L260 or
(Ref. Section 71-00-00). R260 (Ref. Section 53-30-00).
(7). Remove bolts (1) and washers (2) which (7). Install fixed panel assembly (Ref
secure upper inlet assembly (3) to Section 53-30-00).
Page 415
53-30-00 Original
1 (15 PL)
2 (15 PL)
9G53-116
1. BOLT 3. ENGINE UPPER INLET ASSEMBLY
2. WASHER 4. FIREWALL ASSEMBLY
Figure 409. Engine Upper Inlet Assembly
Page 416
Original 53-30-00
13. AntiTorque Inlet Screen Assembly (4). Remove bolts (4) and washers (5) which
secure duct assembly (3) to upper deck.
A. Inlet Screen Assembly Removal
(5). Lift and remove inlet duct assembly (3)
(Ref. Figure 410) from middle inlet duct (8) and firewall.
B. Inlet Assembly Installation
CAUTION
(Ref. Figure 410)
FOD
FOD
Screws utilized to secure inlet screen as CAUTION
sembly are captive-type fasteners and
should only be removed from assembly for (1). Position and align mounting holes of
replacement. inlet assembly (3) to upper deck and
install bolts (4) and washers (5). Torque
(1). Disengage captive screws (1). screws.
(2). Remove inlet screen assembly (2). (2). Install swashplate aft fairing assembly
B. Inlet Screen Assembly Installation
(3). Install left and right engine cowl
(Ref. Figure 410) assemblies (Ref. Section 53-30-00).
FOD (4). Install left and right exhaust ejector
CAUTION
cowls (Ref. Section 53-30-00).
(1). Position inlet screen assembly (2) over 15. Middle Inlet Duct Assembly (F4)
inlet cavity of upper inlet duct assembly
and align mounting holes. A. Middle Inlet Duct Assembly Removal
(2). Engage captive screws (1) with nut (Ref. Figure 410)
plates on inlet assembly (3) and torque (1). Remove forward duct assembly F1, F2
screws. and F3 (Ref. Section 53-30-00).
14. Upper Inlet Duct Assembly (T240) (2). Remove upper inlet duct assembly
T240 (Ref. Section 53-30-00).
A. Inlet Assembly Removal
(3). Remove bolts (6) and washers (7) which
(Ref. Figure 410) secure middle inlet duct assembly (8) to
fan support structure (9).
FOD
CAUTION NOTE: Sealing compound used between duct
assembly and upper deck is actually a self-
(1). Remove left and right exhaust ejector forming gasket. Care should be taken not to
cowls L270, R270 (Ref. Section damage this gasket when removing duct as
53-30-00). sembly.
(2). Remove left and right engine cowl (4). Using a putty knife (or equivalent), if
assemblies L260, R260 (Ref. Section necessary, carefully break seal between
53-30-00). faying surfaces of duct assembly, upper
deck and fan support structure.
(3). Remove swashplate aft fairing assem
bly T220 (Ref. Section 53-30-00). (5). Remove duct assembly.
Page 417
53-30-00 Original
B. Middle Inlet Duct Assembly Installation Release Agent (C417)

(Ref. Figure 410)
(Ref. CSPSPM)
Item Nomenclature (d). Apply release agent (C417) to contact
surfaces of duct, upper deck and fan
C417 Release Agent support structure. Allow releasing
C419 Alcohol, Isopropyl agent to dry before applying sealant.
C209 Sealing Compound, Dichromate Cured
NOTE: Do not apply sealant in nutplate re

NOTE: Steps 1 and 2 apply only if forming a gions of duct assembly.
new seal. If the original seal is not damaged,
start with Step 3. (2). Apply a coat of sealing compound
(C209) to contact surface of middle inlet
(1). Prepare contact surfaces of middle inlet duct assembly (8).
duct assembly (8), upper deck (10) and
fan support structure (9) for sealant. (3). Secure duct to fan support structure
(a). Wipe contact surfaces with a clean, bolts.
lint free cloth dampened in isopropyl
alcohol (C419). (4). Install forward duct assembly F1, F2
(b). Wipe surfaces before alcohol dries. and F3 (Ref. Section 53-30-00).
(c). Allow to air dry for a minimum of ten (5). Install upper inlet duct assembly T240
minutes. (Ref. Section 53-30-00).
Page 418
2
1
5 (4 PL)
3 4 (4 PL)
10
6 (5 PL)
7 (5 PL)
ENGINE AND FIREWALL
NOT SHOWN
9G53-115
1. CAPTIVE SCREW 6. BOLT
2. INLET SCREEN ASSEMBLY 7. WASHER
3. UPPER INLET DUCT ASSEMBLY (T240) 8. MIDDLE INLET DUCT ASSEMBLY (F4)
4. BOLT 9. FAN SUPPORT STRUCTURE
5. WASHER 10. UPPER DECK
Figure 410. Upper and Middle Inlet Duct Assemblies
Page 419
53-30-00 Original
16. Forward Duct Assembly, AntiTorque Fan (5). Remove wire harness W130.
(F1, F2 and F3)
A. Forward Duct Removal (a). Remove bolts (13), nuts (14) and
washers (16) securing clamps (17)
(Ref. Figure 411) and harness (18) to inside of right
(1). Remove baggage compartment soft fairing half (10).
insulation roof panels (Ref. Section
25-50-00).
(b). Remove lockwire and detach electri
NOTE: Sealing compound used between duct cal connector P434 from azimuth
assembly and upper deck is actually a self- sensor.
forming gasket. Care should be taken not to
damage this gasket when removing duct as
sembly. (c). Remove lockwire and detach electri
cal connector P433 from vibration
(2). Using a putty knife (or equivalent), if sensor.
necessary, carefully break seal between
faying surfaces of duct assembly and
upper deck. (6). Remove right half of fairing/centerbody.
(3). Remove aft section of forward duct
assembly. (a). Remove bolts (13), nuts (14) and
washers (6) which secure fairing half
(a). Remove bolts (1) and washers (2)
(10) to inside contour of duct assem
which fasten duct assembly (3) to
bly (7).
forward edge of fan support structure
(4).
(b). Remove bolts (5) and washers (6) (b). Remove bolt (15) securing fairing half
which fasten aft section of duct to right-hand strut of fan support
assembly (3) to forward section (7). frame.
(c). Remove bolts (5) and washers (6)

which fasten duct assembly (3) to (7). Remove forward section of duct assem
underside of upper deck. bly.
(4). Remove left half of fan fairing/center

body. (a). Remove lockwire and detach electri
cal connector P390 from receptacle
(a). Remove screw (8) and washer (6) J390.
which fasten fairing/centerbody
assembly (9 and 10) to upper inlet
duct cover (11). (b). Remove bolts (5) and washers (6)
which secure duct assembly (7) to
(b). Remove screws (12) which fasten left
half (9) of fairing to right half (10). upper deck.
(c). Remove bolts (13), nuts (14) and

washers (6) securing forward end of (8). Remove drive shaft cover (19) from
fairing half (9) to inside contour of underside of upper deck by removing
duct assembly (7). bolts (5) and washers (6).
(d). Remove bolts (15) securing fairing

half (9) to left-hand and bottom (9). Install protective caps on all electrical
struts of fan support structure (4). connectors and receptacles.
Page 420
Original 53-30-00
B. Forward Duct Installation Sealing Compound (C209)
(Ref. Figure 411)
Consumable Materials NOTE: Do not apply sealant in nutplate re

(Ref. CSPSPM) gions of duct assembly or drive shaft cover.
Item Nomenclature
(3). Attach drive shaft cover (19) to the
C417 Release Agent
underside of upper deck.
C209 Sealing Compound, Dichromate Cured (a). Apply a coat of sealing compound
(C209) to contact surface of drive
C701 Lockwire shaft cover (19).
(b). Align cover with nutplates in upper
NOTE: Steps (1). and (2). apply only if forming deck.
a new seal. If the original seal is not dam
aged, start with step (3).. (c). Secure cover to deck with bolts (5)
and washers (6). Torque bolts.
(1). Prepare fairing-to-fairing and fairing- (4). Attach forward section of duct assembly
to-deck contact surfaces of ducts (3 and to underside of upper deck.
7), drive shaft cover (19) and underside
of upper deck for installation. (a). Apply sealing compound (C209) to
contact surface of forward section of
Alcohol, Isopropyl (C419) duct assembly (7).
(b). Align duct assembly (7) with holes in
upper deck and nut plates in middle
duct assembly.
(c). Secure duct (7) to deck with bolts (5)
(a). Wipe contact surfaces with a clean, and washers (6). Torque bolts.
alcohol (C419). (d). Wipe off excess sealing compound
from edges of duct assembly.
(b). Wipe surfaces before alcohol dries. (5). Install wire harness W130 with
grommet through hole at center of duct
(c). Allow to air dry for a minimum of ten assembly.
minutes.
(a). Move wire harness (18) connector
P390 through grommet to approxi
mate length of 7.10 in. forward of
duct assembly.
(b). Secure grommet into duct assembly
(7).
(d). Apply release agent (C417) to contact (c). Attach connector P390 to receptacle
surfaces of cover (19) and fore and aft J390. Safety with lockwire (C701).
sections of duct assembly (3 and 7).
(d). Seal wire harness and grommet to
Allow releasing agent to dry before
duct assembly using sealing com
applying sealant.
pound (C209).
(2). Set aft section of duct assembly (3) (6). Install right half of fan fairing/center
aside for later installation. body assembly.
Page 421
(a). Position fairing (10) around right (d). Secure centerbody fairing assembly
side of fan drive shaft. to upper inlet duct cover (11) with
screw (8) and washer (6).
(b). Attach wide radius of fairing (10) to
clip on right-hand fan support strut (10). Torque all hardware installed in the
with bolt (15). preceding steps.
(c). Attach forward end of fairing half to Sealing Compound (C209)
inside contour of forward duct (7)
with bolts (13), nuts (14) and wash
ers (6).
(7). Install wire harness W130 inside right
centerbody fairing half. NOTE:
Do not apply sealant in nutplate regions
(a). Secure wire harness to fairing (10) of duct assembly.
with clamps (17), using bolts (13),
washers (16) and nuts (14). Torque Apply sealing compound only if forming a
nuts. new seal. If the original seal is not dam
aged, proceed with final installation of
(b). Attach electrical connector P433 to duct assembly.
vibration sensor. Safety with lock
wire (C701). (11). Install aft section of duct assembly.
(c). Attach electrical connector P434 to (a). Apply sealing compound (C209) to
azimuth sensor. Safety with lockwire surfaces of aft duct section (3) where
(C701). it contacts the upper deck, forward
duct section (7) and forward edge of
(8). Inspect to ensure that no portion of fan support structure (4).
wire harness or fairing is chafing
against fan drive shaft or coupling. (b). Align aft duct (3) with nutplates
between forward section of duct and
(9). Assemble left half of fairing /centerbody forward edge of fan support struc
to right half. ture.
(a). Attach left fairing half (9) to clips on (c). Install bolts (5) and washers (6)
bottom and left-hand struts of fan along forward and top edges of duct.
support frame with one bolt (15)
each. (d). Install bolts (1) and washers (2)
along aft edge of duct.
(b). Attach forward end of fairing half to
inside contour of forward duct (7) (e). Torque bolts. Wipe off excess sealant
with bolts (13), washers (6) and nuts as required.
(14).
(12). Install baggage compartment roof
(c). Fasten centerbody fairing halves insulation panel (Ref. Section
together with screws (12). 25-50-00).
Page 422
Original 53-30-00
5 5
6 6
6
8 5
6
5 18
6
12
13 (2 PL)
14 (2 PL)
15 16 (2 PL)
18 4 17 (2 PL)
13 (4 PL) LOOKING INBOARD
14 (4 PL) LEFT SIDE
6 (4 PL) 10
1 (10 PL)
2 (10 PL)
11 3
19 9G53-023A
1. BOLT 11. UPPER INLET DUCT COVER

2. WASHER 12. SCREW
3. AFT SECTION OF FORWARD DUCT (F2) 13. BOLT
4. FAN SUPPORT STRUCTURE 14. NUT
5. BOLT 15. BOLT
7. FORWARD SECTION OF DUCT (F2) 17. CLAMP
8. SCREW 18. WIRE HARNESS
9. LEFT HALF OF FAIRING/CENTERBODY (F3) 19. DRIVE SHAFT COVER (F1)
10. RIGHT HALF OF FAIRING/CENTERBODY (F3)
Figure 411. Forward Duct and Fairing / Centerbody, AntiTorque Fan
Page 423
53-30-00 Original
17. Aft Duct Assembly, AntiTorque Fan (F6, (1). Put upper center diffuser in its
F7, and F8) installed position.
A. Lower Center Diffuser and Access Panel (2). Install screws (6) and washers (2).
Removal
(Ref. Figure 412) (3). Install screws (7) and washers (8).
(1). Remove baggage compartment roof Do not torque stator vane
insulation panel (Ref. Section CAUTION screws too much, damage to sta
25-50-00). tor vanes can occur.
(2). Release adjustable tension latches (1).
(4). Install screws (9) and washers (10).
(3). Lower lower center diffuser and access Torque screws 3-6 in-lb (0.339-0.678
panel (5) until locating pins (4) disen Nwm) plus drag torque.
gage from holes in upper center diffuser
(3) and remove panel. (5). Torque screws (6 and 7).
B. Upper Center Diffuser Removal
D. Lower Center Diffuser and Access Panel
(Ref. Figure 412) Installation.
(1). Remove lower diffuser and access (Ref. Figure 412)
panel.
(2). Remove screws (6) and washers (2). Make sure pilot directional ped
CAUTION als are approximately in their
(3). Remove screws (7) and washers (8). center position, damage to fan blades and
stators can occur.
NOTE: If fan pitch control rod is installed, turn
upper center diffuser to go around rod.
(1). Put lower diffuser and access panel in
(4). Remove screws (9) and washers (10). its installed position and engage
Remove upper center diffuser (3). locating pins.
C. Upper Center Diffuser Installation (2). Latch adjustable tension latches.

(Ref. Figure 412)
NOTE: If fan pitch control rod is installed, turn insulation panel (Ref. Section
upper center diffuser to go around rod. 25-50-00).
Page 424
9 (6 PL)
10 (6 PL)
9
10 9
10
2
6
8 (7 PL) 2 (4 PL)
7 (7 PL)
6 (4 PL) 4 (4 PL)
LOOKING AFT
9G53-024A
1. ADJUSTABLE TENSION LATCHES 6. SCREW
2. WASHER 7. SCREW
3. UPPER CENTER DIFFUSER (F6) 8. WASHER
4. LOCATING PINS 9. SCREW
5. LOWER CENTER DIFFUSER AND ACCESS PANEL (F7, 10. WASHER
F8)
Figure 412. Aft Duct Assembly, AntiTorque Fan
Page 425
18. Diverter Plate and Aft Diffuser Assembly B. Diverter Plate and Aft Diffuser
Installation
A. Diverter Plate and Aft Diffuser Removal
(Ref. Figure 413)
(Ref. Figure 413)
(1). Remove lower center diffuser and (Ref. CSPSPM)
access panel F7 and F8 (Ref. Section Item Nomenclature
53-30-00). C417 Release Agent
(2). Remove upper center diffuser F6 (Ref.
Section 53-30-00).
(3). Disconnect control rod from anti-torque (1). Install anti-torque controls in diverter
fan (Ref. Section 67-20-00). plate assembly (Ref. Section 67-20-00).
(4). Disconnect force limiting control rod (2). Prepare contact surfaces of diverter
from outer bellcrank (Ref. Section plate (18), aft diffuser halves (21 and
67-20-00). 22), duct assembly halves (5 and 15)
and tailboom attachment ring (16) for
(5). Remove screws (1 and 2) and washers installation.
(3) which secure electrical access cover Alcohol, Isopropyl (C419)
(4) to lower duct assembly (5).

clamps (8 and 9) which secure wire
harness (10) and coax cable (11) to
airframe. (a). Wipe contact surfaces with a clean,
(7). Disconnect wire harness (10) and coax alcohol (C419).
cable (11). (b). Wipe surfaces before alcohol dries.
(8). Remove screws (12) and washers (13) (c). Allow to air dry for a minimum of ten
which secure lower duct (5) to brackets minutes.
(14) on either side of upper duct
assembly (15).

which secure lower duct to tailboom
attachment ring (16).
(d). Apply release agent (C417) to contact
(10). Remove screws (19) and washers (20) surfaces.
which secure lower duct and diverter (e). Allow releasing agent to dry before
plate with aft diffuser (21 and 22) to proceeding to next step.
upper duct.
(3). Assemble aft diffuser halves (21 and
(11). Remove nylon fasteners (17) from 22) to diverter plate (18) and secure
outboard edges of diverter plate (18). with quarter turn fasteners (23).
Page 426
Sealing Compound (C205) (6). Route wire harness (10) and coax cable
(11) through opening in left side of
lower duct and secure to airframe with
clamps (8 and 9), screw (6) and washer
(7). Torque screw. Attach electrical
(4). Apply a fillet bead of sealing compound connectors.
(C205) along contact surfaces of
diverter plate (18) and aft diffuser (7). Install electrical access cover (4) with
halves (21 and 22). screws (1 and 2) and washers (3).
(5). Install diverter plate (18) and lower Sealing Compound (C205)
duct assembly (5).
(a). Align holes in outboard edges of
diverter plate (18) with nutplates in
outboard edges of upper duct assem
bly (15). (8). Apply a fillet bead of sealing compound
(b). Install nylon fasteners (17) in (C205) along contact surfaces of aft
outboard edges of diverter plate (18). duct, electrical access panel and
diverter plate.
(c). Attach lower duct assembly to under
side of diverter plate and upper duct (9). Connect force limiting control rod to
assembly with screws (19) and outer bellcrank (Ref. Section
washers (20). 67-20-00).
(d). Attach lower duct to tailboom (10). Connect control rod to anti-torque fan
attachment ring (16) with screws (2) (Ref. Section 67-20-00).
and washers (3).
(e). Attach lower duct to brackets (14) (11). Install upper center diffuser (Ref.
with screws (12) and washers (13). Section 53-30-00).
(f). Torque all attaching hardware (12). Install lower center diffuser and access
installed in the preceding steps. panel (Ref. Section 53-30-00).
Page 427
53-30-00 Original
21
11 15
6 18
7
8
9 17 22
14
2 (12 PL)
16 3 (12 PL)
10 1 (2 PL)
23 (4 PL)
5
4
20 (6 PL)
19 (6 PL)
12 (2 PL)
13 (2 PL)
9G53-108
1. SCREW 13. WASHER
2. SCREW 14. BRACKET
3. WASHER 15. FAN UPPER DUCT ASSEMBLY (F5)
4. ELECTRICAL ACCESS COVER 16. TAILBOOM ATTACHMENT RING
5. FAN LOWER DUCT ASSEMBLY (F9) 17. NYLON FASTENERS
6. SCREW 18. DIVERTER PLATE ASSEMBLY
7. WASHER 19. SCREW
8. CLAMP 20. WASHER
9. CLAMP 21. AFT DIFFUSER, UPPER
10. WIRE HARNESS 22. AFT DIFFUSER, LOWER
11. COAX CABLE 23. QUARTER TURN FASTENER
12. SCREW
Figure 413. Diverter Plate and Aft Diffuser Assembly
Page 428
Original 53-30-00

INSPECTION/TEST
1. Fuselage Upper Deck and Aft Area 2. Latch and Striker Adjustment (EARLY
Inspections CONFIG)
A. Cowling Latch Adjustment
A. Fuselage Upper Deck Inspection
(Ref. Figure 601)
(1). Visually inspect top of upper deck
structure for cracks, mechanical NOTE:
damage and security of mechanical Adjustment of cowling latches for access
fasteners. No damage allowed. doors, L155, L210, R155, and R210 is typ
ical.
(2). Visually inspect top of upper deck Adjustment of the cowling latch affects
structure for evidence of fluid leakage. alignment of the latch shear pin and ac
Identify item causing leaks and repair. cess door striker. Adjustment of the latch
will affect alignment in the direction
(3). Visually inspect firewall panels, and shown in Figure 601.
engine inlet assemblies for cracks,
mechanical damage, and security of (1). Determine amount and direction of
mechanical fasteners and removable adjustment required.
attachment hardware. No damage (2). Remove cowling latch (2) and latch
allowed. shim (3) from door panel (1) (Ref.
Section 53-30-00).
(4). Visually inspect cowl attachment
angles for cracks, mechanical damage, (3). Measure thickness of shim or total shim
and security of mechanical fasteners stack.
and receptacles for attachment of cowls. (4). Adjust shim thickness by amount of
No damage allowed. adjustment required. Adjust shim
thickness by peeling laminate thick
B. Fuselage Aft Area Inspection nesses from existing shim and/or
replacing shim with full thickness shim
(1). Visually inspect anti-torque fan and adjusting thickness as required.
support structure for cracks, mechani
cal damage and security of mechanical (a). Nominal shim thickness is .080-in.
fasteners. No damage allowed. with .002-in. thick laminates.
(b). On forward access doors, L155 and
(2). Visually inspect rear fuselage shells, R155, the maximum shim thickness
forward and aft anti-torque fan at each latch position is 0.080-inch
frames and attachments. No damage or one full shim thickness.
allowed.
(c). On the transmission access doors,
(3). Visually inspect anti-torque fan L210 and R210, the maximum shim
ducting for cracks, mechanical damage, thickness at each latch position is
and security of mechanical fasteners 0.240-inch or three full shim thick
and removable attachment hardware. nesses.
No damage allowed.
(5). Reinstall cowling latch with adjusted
latch shim thickness (Ref. Section
(4). Visually inspect interior and exterior of 53-30-00).
rear fuselage shell assemblies for
cracks, mechanical damage, and (6). Close access door and check for proper
security of mechanical fasteners. No latch operation. Repeat adjustment if
damage allowed. required.
Page 601
53-30-00 Original
LH SHOWN, RH OPPOSITE
90007610100-101-c-f
9G53-074
1. DOOR PANEL 3. LATCH SHIM

2. COWLING LATCH
Figure 601. Cowling Latch Adjustment (EARLY CONFIG)
B. Access Door Striker Adjustment (2). Loosen bolts (1) securing striker plate
(2) sufficiently to allow movement of
striker plate over serrations of striker
(Ref. Figure 602)
adjustment plate (3).
NOTE: (3). Adjust position of striker plate to

striker adjustment plate. Serrations
Adjustment of strikers for access doors,
allow movement in increments of
L155, L210, R155, and R210, is typical.
0.050-inch.
Adjustment of the access door striker
plate affects alignment of the latch shear (4). Insure serrations on striker plate are
pin with the striker plate. Adjustment of fully engaged with serrations on striker
the striker plate will affect alignment in adjustment plate and torque bolts.
the direction shown in Figure 602.
(5). Close access door (4) and check for
(1). Determine amount and direction of proper latch operation. Repeat adjust
adjustment required. ment if required.
Page 602
Original 53-30-00
3 LEFT SIDE, LOOKING INBOARD

2
2 1 (2 PL)
1 (2 PL) 2
1 (2 PL) LOOKING FWD

3
3
LOOKING AFT
LOOKING AFT
9G53-075
1. BOLT 3. STRIKER ADJUSTMENT PLATE
2. STRIKER PLATE 4. ACCESS DOOR
Figure 602. Access Door Striker Adjustment (EARLY CONFIG)
Page 603
3. AntiTorque Fan Diffuser Stator Vane

Inspection (Area 6)
(Ref. Figure 412)
(Ref. Table 601)
Table 601. AntiTorque Fan Stator Vane Damage Limits
Maximum Maximum
Examine Serviceable Limits Repairable Limits Repair Procedure
Stator vane around Cracks that are not Maximum permitted crack Lightly clean crack, use
threaded insert for radial repaired are not permitted. length, 0.375 in. (9.53 scouring pad (C817) and
cracks. mm). isopropyl alcohol (C419).
Seal crack, use
cyanoacrylate adhesive
(C442). If necessary after
adhesive is cured, make
damage smooth. Use 400
grit abrasive cloth (C810)
(or finer). Record length
and location of crack.
Page 604

REPAIR
1. Access Door Assembly (3). Remove cowling latch (2) and latch
shim(s) (3). Retain latch shim(s) and
A. Cowling Latch Replacement (EARLY mounting hardware in sets marked
CONFIG) with installed location.
(Ref. Figure 801)
(4). Position replacement cowling latch (2)
NOTE: Replacement of cowling latches on ac and shim(s) (3) on interior surface of
cess door assemblies, L155, L210, R155, access door panel (1).
and R210, is typical.
(1). Open access door (L155, L210, R155, or (5). Install screws (4), washers (5), and nuts
R210) to gain access to cowling latch (6) and torque nuts.
mounting hardware. (Ref. Section
06-00-00) (6). Close access door and check for proper
operation of door latch. Adjust access
(2). Remove screws (4), washers (5), and door latch and/or striker if necessary.
nuts (6). (Ref. Section 53-30-00)
Page 801
53-30-00 Original
4 (4 PL)
5 (4 PL)
6 (4 PL)
LH SHOWN, RH OPPOSITE
9G53076
1. ACCESS DOOR PANEL 4. SCREW
2. COWLING LATCH 5. WASHER
3. LATCH SHIM 6. NUT
Figure 801. Cowling Latch Replacement (EARLY CONFIG)
B. Forward Access Door Seal Replacement
CAUTION
(Ref. Figure 802) During seal replacement place door as
sembly on appropriate pads to avoid dam
age to composite door skin.
Consumable Materials During seal removal use appropriate non
(Ref. CSPSPM) metallic scraper, if required, to avoid
Item Nomenclature damage to composite seal lands.
(1). Remove access door assembly (Ref.
Section 53-30-00).
NOTE: Seal replacement for forward access (2). Remove seals (2) and (3) from access
doors, L155 and R155 is typical. door panel (4).
Page 802
Original 53-30-00
(3). Clean and remove residue from seal

lands (Ref. CSP-SPM, Section CAUTION
20-50-00). During seal replacement place door as
sembly on appropriate pads to avoid dam
(4). Prior to removal of protective film from age to composite door skin.
seal surface with adhesive, position seal During seal removal use appropriate non
material on seal lands of access door metallic scraper, if required, to avoid
panel (4) and mark and trim to re damage to composite seal lands.
quired length.
(1). Remove access door assembly (Ref.
Section 53-30-00).
(5). Position 0.125 in (3.18 mm) thick seal
material (2) on upper and lower seal (2). Remove seals (2) and (3) from access
lands flush to edge of door panel. door panel (1).
(3). Clean and remove residue from seal
(6). Position 0.062 in (1.57 mm) thick seal lands (Ref. CSP-SPM, Section
material (3) on forward and aft seal 20-50-00).
lands flush to edge of door panel.
(4). Prior to removal of protective film from
seal surface with adhesive, position seal
(7). At corner intersections of the forward
material on seal lands of access door
and lower seal, and the aft and lower panel (1) and mark and trim to re
seal, trim seal material to form approxi
quired length.
mate 45 degree butt joints.
(8). Trim upper ends of forward and aft material (2) on upper seal land flush
seals, and forward and aft ends of with edge of seal land. Trim forward
upper seal to match end trim of seal and aft ends to match end trim of seal
land. land.
(9). Prepare seal lands for application of material (3) on lower, forward, and aft
seals (Ref. CSP-SPM, Section seal lands flush to edge of door panel.
20-50-00).
(7). At the corner intersections of the
forward and lower seals, and the aft
(10). Remove protective film from seal and and lower seals, trim ends of seal
apply seal to appropriate seal land. Use material to form approximate 45 degree
moderate hand pressure to insure butt joints.
proper adhesion to seal land.
(8). Trim upper end of forward seal to
match edge trim of door panel.
C. Transmission Access Door Seal
Replacement (9). Trim upper end of aft seal diagonally so
that forward corner is 15.70 in (39.88
(Ref. Figure 802) cm) and aft corner is 11.30 in (28.7
cm) from the lower end of the seal land
measured along the contour of the seal
Consumable Materials land.
(Ref. CSPSPM) (10). Prepare seal lands for application of
Item Nomenclature seals (Ref. CSP-SPM, Section
C425 Solvent, Cleaning 20-50-00).
(11). Remove protective film from seal and
apply seal to appropriate seal land. Use
NOTE: Seal replacement for transmission ac moderate hand pressure to insure
cess doors, L210 and R210 is typical. proper adhesion to seal land.
Page 803
53-30-00 Original
3
3
2 2 2 2

LEFT SIDE
9G53081
1. TRANSMISSION ACCESS DOOR PANEL 3. 0.062IN. SEAL
2. 0.125IN. SEAL 4. FORWARD ACCESS DOOR PANEL
Figure 802. Transmission Access Door and Forward Access Door Seals
2. Support Assembly (3). Clean and remove residue from seal
surface (Ref. CSP-SPM, Section
A. Support Assembly Duct Frame Seal 20-50-00).
Replacement
(Ref. Figure 803) (4). Prior to removal of protective film from
surface with adhesive, position seal
material on inner surface of duct frame
on support assembly and mark and
(Ref. CSPSPM)
trim required seal length.
Item Nomenclature
(a). Position seal material flush to 0.10
in (2.54 mm) from edge of frame.
NOTE: Seal replacement for the duct frame of
the left and right support assemblies is typi (b). Position seal material around entire
cal. periphery and trim ends to form a
During seal removal use ap butt joint.
CAUTION propriate nonmetallic scraper, if
required, to avoid damage to composite duct (5). Prepare seal surface for application of
frame. seal (Ref. CSP-SPM, Section
20-50-00).
(1). Remove support assembly (1) (Ref.
Section 53-30-00).
(6). Remove protective film from seal
(2). Remove seal (2) from entire periphery material and apply to surface using
on inner surface of duct frame on moderate hand pressure to ensure
support assembly (1). proper adhesion.
Page 804
Original 53-30-00
900 CONFIG
NACA CONFIG 9G53114A
1. SUPPORT ASSEMBLY
2. SEAL
Figure 803. Support Assembly Duct Frame Seal
Page 805
53-30-00 Original
3. Swashplate Aft Fairing Assembly (T220) (6). Remove handhold and drill transferred
hole patterns. Drill rivet and turnlock
A. Oil Dipstick Handhold Replacement fastener holes.
(Ref. Figure 804) (7). Position seal (6), prior to removal of
protective film on surface with adhe
sive, around perimeter of handhold
adjacent to edges on inboard surface of
(Ref. CSPSPM)
flanges.
Item Nomenclature
C425 Solvent, Cleaning (a). Cut ends to form a butt joint.
C211 Sealing Compound, Corrosion Inhibitive (b). Cut 0.374-0.381 in (9.5-9.68 mm)
C212 Sealing Compound, Corrosion Inhibitive diameter holes in seal at turnlock
C213 Sealing Compound, Corrosion Inhibitive fastener locations to clear outside
C214 Sealing Compound, Corrosion Inhibitive diameter of retaining washers.
C309 Primer (8). Prepare flanges on inboard surface of
handhold for application of seal (Ref.
NOTE: Replacement of the left and right oil
dipstick handholds is typical. (9). Remove protective film from seal and
apply seal to inboard surfaces of
(1). Remove rivets (2) securing hinge (5) to handhold flanges. Use moderate hand
oil dipstick handhold (1) and remove pressure to ensure proper adhesion.
handhold.
(10). Install turnlock fastener studs (3) and
(2). Remove turnlock fastener studs (3) and retaining washers (4).
retaining washers (4).
(3). Position replacement handhold (1) on
swashplate aft fairing assembly.
(a). Ensure handhold overlaps forward
edge of opening in fairing assembly Primer (C309)
0.53 in (13.46 mm).
(b). Ensure handhold overlaps outboard
edge of opening in fairing assembly
1.17 in (2.97 cm). (11). Attach handhold to hinge (5) on fairing
assembly using rivets (2).
(4). Fold hinge (5) over flange of handhold
and transfer existing rivet hole pattern (a). Install rivets with wet sealing
in hinge to flange of handhold. compound (C211), (C2120, (C213), or
(C214) or primer (C309).
(5). Transfer existing turnlock receptacle
locations on fairing assembly to (b). Install rivets with bulb ends out
outboard flange of handhold. board.
Page 806
Original 53-30-00
2 (5 PL)
5
1
3 (2 PL)
4 (2 PL)
9G53084
1. HANDHOLD 4. RETAINING WASHER
2. RIVET 5. HINGE
3. STUD 6. SEAL
Figure 804. Oil Dipstick Handhold
Page 807
53-30-00 Original
4. Engine Cowl Assembly (3). Remove bonding material residue and

clean surfaces (Ref. Section 20-20-00).
A. Engine Cowl Insulation Replacement
(4). Temporarily position replacement cowl
(Ref. Figure 805) insulation (1) on interior surface of
engine cowl panel (2). Transfer loca
Consumable Materials tions of cowl attachment fasteners and
(Ref. CSPSPM) mark required edge trim if required.
Item Nomenclature
(5). Remove insulation and cut 0.38 in
C415 Adhesive Sealant
(9.65 mm) diameter holes at trans
ferred fastener locations and trim any
NOTE: Replacement of the left and right en required material from edges as
gine cowl insulation is typical. marked.
(6). Prepare interior surface of cowl panel
CAUTION for bonding (Ref. CSP-SPM, Section
During insulation replacement place cowl 20-50-00).
assembly on appropriate pads to avoid Adhesive Sealant (C415)
damage to composite cowl skin.
During insulation removal use appropri
ate nonmetallic scraper, if required, to
avoid damage to composite cowl skin.
(7). Apply adhesive sealant (C415) to
(1). Remove engine cowl assembly (Ref.
interior surface of cowl panel (Ref.
Section 53-30-00).
CSP-SPM, Section 20-50-00)
(2). Separate and remove engine insulation
(1) from engine cowl panel (2). (a). At top edge of cowl panel apply
required sealant film thickness 0.22
(a). Initiate removal of the insulation at in (5.59 mm). wide between bend
the mounting flanges around the line and rivet attachment line of both
perimeter of the cowl. stiffeners.
(b). Insulation is bonded to the cowl (b). At forward, aft and lower edges of
panel around the entire perimeter of cowl panel apply required sealant
the panel, along the full length of the film thickness starting from the edge
two composite stiffening ribs, and of the panel and equivalent in width
around the perimeter of both air inlet to the width of the attachment flange
screens. of the insulation.
Page 808
Original 53-30-00
TOP VIEW LOOKING OUTBOARD

LOOKING UP LEFT SIDE
9G53082
1. ENGINE INSULATION
2. ENGINE COWL PANEL
Figure 805. Engine Cowl Insulation Replacement

53-30-00 Original
Section
534000
Tailboom
TAILBOOM
1. Tailboom General On helicopters with the thruster extension, the
tailboom/thruster left and right upper fairing
(Ref. Figure 1) assemblies cover and fair the empennage to
The major components contained in this area tailboom, and the upper half of the tailboom to
of the fuselage are the tailboom assembly, thruster extension attach points. The tail
tailboom bumper, tailboom/thruster, left and boom/thruster lower fairing assembly covers
right upper fairing assemblies, and tailboom/ and fairs the lower portion of the empennage
thruster lower fairing assembly. attachment frames and the lower half of the
tailboom to thruster extension attach point.
2. Tailboom Bumper Attachment of the fairing assemblies is by
screws.
(Ref. Figure 1)
On helicopters with the thruster extension, the
The tail bumper provides protection for the left and right thruster extension fairing
tailboom assembly and thruster. The tail assemblies cover and fair the tailboom to
bumper is attached to both empennage thruster extension attach point and thruster
attachment frames by mating bosses and extension to thruster attach point. Attachment
clevis type pins. The tailboom bumper is of the fairing assemblies is by screws.
fabricated from aluminum alloy tubing.
Each fairing assembly consists of a composite
3. Tailboom/Thruster Fairing Assemblies fairing panel, self-adhering silicone rubber
seals, and standard hardware. Each fairing
(Ref. Figure 1) panel is fabricated as a monolithic laminate
using multiple plies of aramid/epoxy. Portions
The tailboom/thruster left and right upper of the upper edges of the left and right upper
fairing assemblies cover and fair the empen fairing panels cocured syntactic foam.
nage to tailboom, and the upper half of the
tailboom to thruster attach points. The On helicopters with the thruster extension, the
tailboom/thruster lower fairing assembly tailboom/thruster right upper fairing has one
covers and fairs the lower portion of the vortex generator bonded to it. The tailboom/
empennage attachment frames and the lower thruster right lower fairing has seven vortex
half of the tailboom to thruster attach point. generators bonded to it. The right thruster
Attachment of the fairing assemblies is by extension fairing has ten vortex generators
screws. bonded to it.
Page 1
RH TAILBOOM/THRUSTER
UPPER FAIRING ASSEMBLY LH TAILBOOM/THRUSTER
UPPER FAIRING ASSEMBLY
TAILBOOM ASSEMBLY
TAILBOOM BUMPER
LOWER TAILBOOM/THRUSTER
FAIRING ASSEMBLY
THRUSTER EXTENSION TAILBOOM

FAIRING
VORTEX
GENERATOR
Figure 1. Tailboom Area
Page 2
A. Tailboom Assembly laminate flanges. At the aft end of the

assembly, in the area at and aft of the attach
(Ref. Figure 2) ment of the empennage forward attachment
The tailboom assembly is an essential compo frame, the panel transitions into a combina
nent of the NOTAR anti-torque system and tion of a monolithic laminate and cored panel
incorporates, on the right side of the assembly, incorporating a core of syntactic foam. Along
two air circulation control slots and 20 vortex the lower surface the panel incorporates a
generators on helicopters equipped with the cocured exterior surface skin of aluminum foil.
thruster extension. The air circulation control The slat outer skin panel incorporates a cored
slots, that run nearly the entire length of the center section and monolithic laminate
tailboom, allow anti-torque fan air to exit the peripheral flanges. The panel is fabricated
surface of the tailboom assembly. The exiting using multiple plies of graphite/epoxy cocured
air, in conjunction with the downwash from with a Nomex honeycomb core.
the main rotor, produces an airfoil effect over
the tailboom called the ``Coanda effect. The The slat airfoil consists of a slat airfoil skin
sideward force produced by the airfoil effect and integral doublers and ribs. All components
combines with the force produced by the are monolithic laminates and are fabricated
thruster to exert the required main rotor are using multiple plies graphite/epoxy.
anti-torque force.
The tailboom conduit is fabricated as a
The tailboom assembly incorporates the monolithic laminate tube using multiple plies
provisions for the attachment of the empen of graphite/epoxy.
nage, the thruster extension or thruster,
C. Thruster Extension
thruster controls (Ref. Section 67-20-00), and
electrical harnesses to the aft end of the The thruster extension is installed between
aircraft (Ref. CSP-900WIR-8 Section the tailboom and the thruster. The thruster
98-30-00). extension moves the thruster 21 inches aft to
aid in anti-torque control.
The tailboom assembly is a multiple compo
nent assembly. External components are the The thruster extension is made of a composite
tailboom, slat assembly, fuselage attachment barrel with aluminum attachment frames at
frame, and empennage forward and aft each end. Around the barrel is a two-piece
attachment frames and intercostals. Internal composite fairing support for attachment of
components are the upper and lower airfoils, the fairing assemblies.
slot vanes, upper and lower inlet ramps, slat
spacers, diverter plate and attach flanges, D. Slat Assembly
control cable tube and straps, forward and aft The slat assembly is airfoil shaped and
coaxial covers, wiring cover, and electrical combines with the tailboom to form the
conduits. exterior surface of the completed tailboom
B. Tailboom assembly. The slat assembly is installed into
the open area of the tailboom and forms the
The tailboom detail assembly is a composite lower side of the two air circulation control
sandwich panel that is cylindrical in shape and slots. The slat assembly is retained by tension
is 22.51 inches (57.18 cm) in diameter and type titanium fasteners. Slat spacers are
124.18 inches (315.42 cm) in length. The installed in conjunction with the fasteners to
assembly is a partial cylinder and contains an control the distance between the surface of the
open area along most of the right side. The tailboom and surface of the slat assembly. At
sandwich panel is 0.250 inches (6.35 mm) the forward and aft ends, the exterior and
thick and fabricated of multiple plies of interior surfaces of the slat assembly fair flush
graphite/epoxy cocured with a Nomex honey to the surfaces of the tailboom. The slat
comb core. assembly installs to the fuselage attachment
and empennage attachment frames.
At the forward end and the open area on the
right side of the assembly, the core is tapered The slat assembly consists of the slat outer
and the panel transitions to form monolithic skin, the slat airfoil, and tailboom conduit. All
Page 3
detail components are composite and are the interior surfaces of the tailboom, mating
secondarily bonded to form the assembly using surfaces of the airfoils, and slat assembly. The
a high temperature epoxy adhesive. upper and lower inlet ramps are both nonme
tallic components fabricated from polycarbo
E. Upper and Lower Airfoils nate plastic sheet.
The upper and lower airfoils are air entrance H. Forward Coaxial Cover, Aft Coaxial
control devices on the interior surface of the Cover, and Aft Wiring Cover
tailboom assembly for the air circulation
control slots. The upper airfoil is installed The coaxial and wiring covers allow coaxial
parallel to and immediately above the leading cable and wiring to enter and exit the tailboom
edge of the slat assembly. The lower airfoil is assembly without allowing air to escape. The
installed parallel to and immediately below forward coaxial cover is installed below the
the trailing edge of the slat assembly. Each forward end of the lower air circulation control
airfoil is secondarily bonded and faired to the slot and attached to the forward end or the
interior surface of the tailboom. lower airfoil. The lower inlet ramp overlaps
the upper part of the forward coaxial cover.
The upper and lower airfoils are composite The aft coaxial cover and aft wiring cover are
assemblies consisting of an airfoil skin and installed at the aft end of the slat assembly
several integral support ribs. All components and lower airfoil assembly. Each cover is
within each assembly are fabricated as secondarily bonded and faired to the interior
monolithic laminates using multiple plies of surfaces of the tailboom, mating surfaces of
graphite/epoxy. the airfoils, and slat assembly. The forward
F. Slot Vanes coaxial cover, aft coaxial cover, and aft wiring
cover are both nonmetallic components
The slot vanes function as airflow straighten fabricated from polycarbonate plastic sheet.
ers for the anti-torque fan air exiting the air
circulation control slots on the tailboom I. Fuselage Attachment, Empennage
assembly. In the upper air circulation control Attachment Frames, and Intercostals
slot, sixteen slot vanes are installed equally
spaced between the trailing edge of the upper The fuselage attachment frame is located at
airfoil and the leading edge of the slat assem the forward end of the tailboom assembly, and
bly. In the lower air circulation control slot, provides for attachment of the tailboom
sixteen slot vanes are installed equally spaced assembly to the tailboom attachment ring
between the trailing edge of the slat assembly assembly. The forward and aft empennage
and the leading edge of the lower airfoil. Each attachment frames are located at the aft end
slot vane is secondarily bonded. The slot vanes of the tailboom assembly, and contain the
are nonmetallic components fabricated from provisions for attachment of the horizontal
polycarbonate plastic sheet. stabilizer and thruster assemblies. The left
and right intercostal assemblies are installed
G. Upper and Lower Inlet Ramps between the forward and aft empennage
attachment frames adjacent to the provisions
The upper and lower inlet ramps function as for attachment of the horizontal stabilizer.
air entrance control devices at the forward
ends of the air circulation slots on the interior The fuselage, and forward and aft empennage
surface of the tailboom assembly. The upper attachment frames, are machined from
inlet ramp is installed at the forward end of aluminum alloy stock. The left and right
the upper air circulation control slot and intercostals are fabricated from aluminum
overlaps the upper airfoil and leading edge of alloy sheet. The fuselage attachment frame is
the slat assembly. The lower inlet ramp is installed using titanium pins and aluminum
installed at the forward end of the lower air collars. The forward and aft empennage
circulation control slot and overlaps the frames are installed using titanium blind
trailing edge of the slat assembly, the lower fasteners. The intercostals are installed using
airfoil, and the forward coaxial cover. Each a combination of titanium pins and aluminum
inlet ramp is secondarily bonded and faired to collars, and titanium blind fasteners.
Page 4
J. Vortex Generators The vortex generators are bonded to the right

side of the tailboom, right tailboom/thruster
The vortex generators are small T shaped extension upper fairing, lower tailboom/thrust
aluminum parts that reduce drag on the er extension fairing, and right thruster
tailboom in right sideward flight. extension fairing.
RH INTERCOSTAL AFT EMPENNAGE
ATTACH FRAME
FORWARD EMPENNAGE LH INTERCOSTAL

ATTACH FRAME
TAILBOOM ASSEMBLY
TAILBOOM
UPPER AIRFOIL
SLOT VANE
RH DIVERTER
ATTACH FLANGE
UPPER
INLET RAMP AFT
WIRING COVER
AFT
COAXIAL COVER
SLOT VANE
LOWER TAILBOOM
INLET RAMP LOWER AIRFOIL
DIVERTER
FORWARD
PLATE
COAXIAL COVER
VORTEX
LH DIVERTER GENERATORS
FUSELAGE ATTACH FLANGE
ATTACH FRAME
THRUSTER EXTENSION VIEW ROTATED
9G53-111A
Figure 2. Tailboom Assembly
Page 5
Page 6
TAILBOOM
1. Tailboom Inspections (Area 7) (g). If installed, examine thruster exten
sion fairing support for cracks, voids,
A. Tailboom Inspection dents, holes, scratches, delamina
(Ref. Figure 201) tions, and correct installation. No
defects permitted.
(1). If installed, examine vortex generators
for damage (ref. Figure 205). No (h). Examine tailboom/thruster fairings
damage permitted. S2, SL1, and SR1 for condition. No
defects permitted.
(2). Remove access panels S2, SL1, and SR1
(ref. Figure 201).
(i). If installed, examine thruster exten
(3). If installed, remove access panels SL8 sion fairings SL8 and SR8 for condi
and SR8. tion. No defects permitted.
(4). Do an external tailboom inspection as (j). Examine anti-collision light and
follows: navigation light for serviceable
NOTE: Do not remove tailboom unless you find condition. Repair or replace as
an indication of cracks, corrosion, or incor necessary (ref. CSP-900RMM-3,
Section 96-40-00).
rect installation.
(a). Examine tailboom attach frame and (k). Examine light lenses for moisture
attach holes for cracks, corrosion, and condensation. If moisture is found,
correct installation. No defects remove lens and clean (ref.
permitted. CSP-900RMM-3, Section 96-40-00).
(b). Examine tailboom surface and (5). Do an internal tailboom inspection as
tailboom circulation control slots for follows:
cracks, voids, dents, holes, scratches,
delamination, and correct installa (a). Examine diverter plate for cracks,
tion. No defects permitted. delaminations, and separation. None
NOTE: Damage to slots can decrease the rotor permitted.
craft performance during a hover.
(b). Examine slot vanes for condition and
(c). Examine empennage attach brackets correct installation. No defects
for cracks, corrosion, and correct permitted.
installation. No defects permitted.
(c). Examine tailboom for missing slot
(d). Examine thruster attach frame and vanes. None permitted.
attach holes for cracks, corrosion, and
correct installation. No defects (d). Examine control cable attach brack
permitted. ets for cracks, corrosion, corrosion,
(e). If installed, examine thruster exten and condition. No defects permitted.
sion attach frame and attach holes
for cracks and corrosion. No defects (e). Examine control cable conduit for
permitted. cracks, separation, and delamination.
None permitted.
(f). If installed, examine thruster exten
sion barrel for cracks, voids, dents, (f). Make sure air circulation area is
holes, scratches, delaminations, and clean and has no unwanted material.
correct installation. No defects If necessary, clean with mild soap
permitted. and water.
Page 201
4
3
1 14
11
19 (16 PL)
13
15
12
19 (16 PL) 2
6
10 8
16
7
18
17
9G53-110A
Figure 201. Tailboom Assembly
Page 202

1. TAILBOOM ASSEMBLY 11. TAILBOOM ATTACH FITTING
2. ACCESS PANEL S2 12. CONTROL CABLE CONDUIT
3. ACCESS PANEL SL1 13. AFT EMPENNAGE ATTACH FRAME
4. ACCESS PANEL SR1 14. CONTROL CABLE FORWARD ATTACH POINTS
5. BUMPER 15. CONTROL CABLE AFT ATTACH POINT
6. BUMPER ASSEMBLY 16. FORWARD EMPENNAGE ATTACH FRAME
7. DIVERTER PLATE 17. THRUSTER EXTENSION FAIRING SUPPORT
8. ACCESS PANEL SL8 18. THRUSTER EXTENSION
9. ACCESS PANEL SR8 19. THRUSTER ATTACH FITTING
10. EMPENNAGE ATTACH FITTINGS 20. SLOT VANE
(6). Install access panels S2, SL1, and SR1. 1). The measurement must be 20.12 to
20.62 inch (51.10 to 52.37 cm).
(7). (Post-SB900-099) Install access
panels SL8 and SR8. (c). Remove Access Panel S2.
(8). Make sure there is clearance of 0.12 to
0.25 inch (3.0 to 6.4 mm) between (d). Examine forward and aft empennage
access panels and rotating cone. attach frames for damage and correct
installation.
B. Tailboom Bumper Inspection
1). No damage or incorrect installa
(Ref. Figure 204) tion permitted.
(1). Examine bumper for correct installa
(e). If installed, examine forward and aft
tion.
thruster extension frames for dam
(a). No defects permitted. age and correct installation.
(2). Examine bumper (5 or 6) for deforma 1). No damage or incorrect installa
tion: tion permitted.
(a). Bumper (5) Measure outer
(f). Examine rotating cone for damage
dimension of tube in the bend radius
at upper end of bumper (5) in two
positions 90 degrees from each other. 1). No damage permitted.
1). If the difference of the two measure
ments is more than 5 percent, the (g). Examine left and right empennage
bumper must be replaced. lower endplates for damage (ref.
Section 53-55-00).
(b). Bumper Assembly (6) Measure
Dimension A from the bottom of the 1). No damage permitted.
tailboom/thruster to the bottom of
the bumper assembly (6). (h). Install Access Panel S2.
Page 203
48
26
27
28 31
29
25
30
50 50
2 23
4 21
6
19
8
17
10
12 15
49 ( 24 PL ) 13
14
16 11
18 9
35 20
7
22
5
36 24 3 TAILBOOM END FITTING
1
43 ( TORQUE SEQUENCE )
33
32 LOOKING FORWARD
38 39
41
47
42
36
37
34 40 44
46 45 47 45 9G53-048A
Figure 202. Tailboom Assembly Installation
Page 204
Legend (Ref. Figure 202

1. BOLT 26. SCREW
2. NUT 27. WASHER
3. BOLT 28. CLAMP
4. BOLT 29. CLAMP
5. BOLT 30. WIRE HARNESS
6. BOLT 31. COAX CABLE
7. BOLT 32. CONTROL CABLE ROD END
8. BOLT 33. DIRECTIONAL BELLCRANK, FS277
9. BOLT 34. COTTER PIN
10. BOLT 35. BOLT
11. BOLT 36. WASHER
12. BOLT 37. NUT
13. BOLT 38. TAB WASHER
14. BOLT 39. JAM NUT
15. BOLT 40. SLEEVE
16. BOLT 41. CONTROL CABLE
17. BOLT 42. SWIVEL
18. BOLT 43. BRACKET
19. BOLT 44. NUT
20. BOLT 45. WASHER
21. BOLT 46. BOLT
22. BOLT 47. JAM NUT
23. NUT 48. TAILBOOM
24. BOLT 49. WASHER
25. ELECTRICAL ACCESS COVER 50. CAPTIVE BOLT
2. Tailboom (8). Disconnect swivel (42) from control

bracket (43).
A. Tailboom Removal
(a). Remove nuts (44), washers (45) and
(Ref. Figure 202) bolts (46) which secure swivel (42) to
(1). Remove baggage compartment soft control bracket (43).
insulation interior panel (ref. Section (b). Remove and discard safety wire from
25-50-00). swivel jam nuts (47).
(2). Remove access panels F7 and F8 (ref. (c). Loosen both swivel jam nuts (47) and
Section 53-30-00). remove forward jam nut from control
(3). Remove electrical access cover (25). cable.
(4). Remove screw (26), washer (27) and (9). Remove tailboom (48) from fuselage.
clamps (28 and 29) which secure wire NOTE: Four persons are necessary to remove
harness (30) and coax cable (31) to the tailboom. Two to support the tailboom
airframe. beneath the empennage, one to support the
(5). Disconnect wire harness (30) and coax tailboom at the forward end, and one to re
(31). move the attach hardware and swivel.
(6). Disconnect control cable rod end (32) (a). Remove bolts (1, 3 through 24) and
from directional bellcrank (33). washers (49) securing tailboom (48)
to fuselage.
(a). Remove and discard cotter pin (34).
(b). Remove nuts (2, 23) and washers (49)
(b). Remove bolt (35), washers (36) and from captive bolts (50).
nut (37).
(c). Slowly remove tailboom from captive
(7). Remove rod end (32), tab washer (38), bolts (50) while removing the swivel
jam nut (39) and sleeve (40) from cable and remaining jam nut (47) from the
(41). control cable.
Page 205
(d). Guide wire harness, coax cable and (b). Align captive bolts in fuselage fitting
control cable through their access with bolt holes in tailboom end
holes while removing tailboom. fitting.
(10). Place tailboom in a suitable cradle. (c). Route control cable through access
Prevent damage to the vertical stabiliz hole and install jam nut and swivel
ers and tailboom bumper. on cable before routing cable through
control bracket.
B. Tailboom Installation
(d). Install tailboom onto captive bolts
(Ref. Figure 202) while routing control cable, wire
harness, and coax cable through
their respective holes.
(Ref. CSPSPM) (e). Install washers and nuts on captive
Item Nomenclature bolts.
C101 Lubricant, Solid Film (f). Install bolts and washers through
C702 Lockwire tailboom end fitting and torque bolts
and nuts following the sequence
shown in Figure 202, starting at bolt
number 1. Torque to 60 in-lb (6.78
NOTE: Four persons are necessary to install the Nm). Repeat torque sequence at 120
tailboom Two to support the tailboom be in-lb (13.56 Nm).
neath the empennage, one to support the tail (5). Clean up any sealant squeeze out at
boom at the forward end, and one to install attach bolts.
the attach hardware and swivel.
(6). Test tailboom for Class R electrical
Lubricant, Solid Film (C101) bond (ref. CSP-SPM).
(7). Attach swivel to control bracket with
bolts, washers, and nuts. Torque nuts.
(8). Thread jam nut onto cable forward of
(1). Spray coat threads of captive bolts (50) swivel. Tighten finger tight.
and bolts (1, 3 through 24) with solid
(9). Install sleeve over end of cable.
film lubricant (C101).
(10). Attach rod end with tab washer and
(2). Clean mating bond prepared areas at jam nut to cable. Torque jam nut and
attach bolts (4, 21) on fuselage and safety with lockwire (C702).
tailboom.
(11). Attach rod end to directional bellcrank
Sealant, Conductive (C229) with bolt, washers, and nut. Torque nut
and install cotter pin.
(12). Rig directional flight controls and
torque and safety swivel jam nuts (ref.
Section 67-10-00).
(3). Apply sealant (C229) to tailboom attach
bolts (4, 21). Install tailboom while (13). Connect wire harness and coax cable.
sealant is wet.
(14). Secure harness and coax to airframe
(4). Attach tailboom to fuselage. with clamps, screw, and washer.
(15). Install electrical access cover.
(a). Align tailboom end fitting with
fuselage end fitting, keep their attach (16). Install access panels F7 and F8 (ref.
surfaces parallel. Section 53-30-00).
Page 206

insulation interior panel (ref. Section
25-50-00).
Page 207
1 (20 PL)
3 (20 PL)
5
6
9 (32 PL)
10 (32 PL)
11
11 8
1 (8 PL)
3 (8 PL)
4 2 (18 PL)
3 (18 PL) 5
WITHOUT THRUSTER EXTENSION
12
7
4
WITH THRUSTER EXTENSION
NOTE: EMPENNAGE NOT SHOWN FOR CLARITY

9G53-007A
1. SCREW 8. RH THRUSTER EXTENSION FAIRING

2. SCREW 9. SCREW
4. LOWER, TAILBOOM/THRUSTER FAIRING ASSEMBLY 11. THRUSTER FRAME
5. UPPER, TAILBOOM/THRUSTER FAIRING ASSEMBLY 12. THRUSTER EXTENSION FAIRING SUPPORT
6. TAILBOOM FRAME 13. THRUSTER EXTENSION
7. LH THRUSTER EXTENSION FAIRING
Figure 203. Tailboom/Thruster and Extension Fairings
Page 208
3. Lower Tailboom/Thruster Fairing B. Upper Tailboom/Thruster Fairing

Assembly (S2) Assembly Installation
A. Lower Tailboom/Thruster Fairing (Ref. Figure 203)
Assembly Removal
(1). Align upper, tailboom/thruster fairing
(Ref. Figure 203) SL1 and SR1 with FWD and AFT
tailboom frames and thruster extension
(1). Remove screws (1, 2) and washers (3). fairing support.
(2). Disconnect electrical connector from (2). Install screws and washers. Torque
tailboom. Remove fairing (4). screws.
(3). Install lower thruster/tailboom fairing.
B. Lower Tailboom/Thruster Fairing
Assembly Installation (4). If tailboom extension is not installed,
make sure there is clearance of 0.12 to
(Ref. Figure 203) 0.25 inch (3.1 to 6.4 mm) between
fairings and rotating cone.
(1). Connect electrical connector to tail
boom. 5. Thruster Extension Fairing Assembly
(SL8, SR8)
(2). Align lower thruster/tailboom fairing
S2 with upper tailboom/thruster fairing A. Thruster Extension Fairing Assembly
SL1 and SR1 FWD and AFT tailboom Removal
frames, and thruster extension fairing
support. (Ref. Figure 203)
(3). Install screws and washers. Torque (1). Remove upper tailboom/thruster
screws. fairing.
(4). If tailboom extension is not installed, Remove fairings SL8 (7) and SR8 (8).
make sure there is clearance of 0.12 to
0.25 inch (3.1 to 6.4 mm) between B. Thruster Extension Fairing Assembly
fairings and rotating cone. Installation
4. Upper Tailboom/Thruster Fairing (Ref. Figure 203)

Assembly (SL1, SR1) (1). Align fairings SL8 and SR8 with
thruster extension fairing support and
A. Upper Tailboom/Thruster Fairing
thruster frame.
Assembly Removal
(2). Install screws and washers. Torque
(Ref. Figure 203) screws.
(1). Remove lower thruster/tailboom (3). Install upper tailboom/thruster fairing.
fairing.
(4). Make sure there is clearance of 0.12 to
(2). Remove screws (1, 2) and washers (3). 0.25 inch (3.1 to 6.4 mm) between
Remove fairing (5). fairings and rotating cone.
Page 209
1
1
3, 4
VIEW LOOKING FWD
9G53-085B
1. COTTER PIN 4. TAILBOOM BUMPER ASSEMBLY
2. TAILBUMPER PIN 5. FWD AND AFT TAILBOOM/THRUSTER FRAMES
3. TAILBOOM BUMPER
Figure 204. Tailboom Bumper
Page 210
6. Tailboom Bumper B. Tailboom Bumper Installation

(Ref. Figure 204)
A. Tailboom Bumper Removal
Item Nomenclature
(1). Remove Access Panel S2. C205 Sealing Compound
(2). Remove cotter pins (1) from tailbumper Sealing Compound (C205)
pins (2).
(a). Discard cotter pins (1).

(1). Apply sealing compound (C205) to the
(3). Remove tailbumper pins (2) from mating surfaces of tailboom bumper (3
forward and aft tailboom frames (5). or 4) and forward and aft tailboom
frames (5) to prevent the movement of
the bumper.
(4). Remove tailboom bumper (3 or 4).
(2). Install bumper (3 or 4) in frames (5)
with tailbumper pins (2) and new cotter
(5). Remove sealing compound from mating pins (1).
surfaces of bumper (3 or 4) and frames
(5). (3). Install Access Panel S2.
Page 211
2
12.15-13.15 IN.
(30.86-33.40 cm)
1
REF. 5
5
REF. 5 REF. 4
3
11.50-12.50 IN.
(29.21-31.75 cm)
VIEW LOOKING
FORWARD
19X 2.75 IN.

(6.99 cm) 16X 6.00 IN.
(15.24 cm)
17.69-18.69 IN.
(44.93-47.47 cm)
2X 1.00 IN.
(2.54 cm)
5.25-5.75 IN.
(13.34-14.61 cm)
19X 3.40 IN. ALONG TAILBOOM SURFACE
(8.64 cm)
9.23-9.73 IN.
(23.44-24.71 cm)
ALONG TAILBOOM SURFACE
VIEW LOOKING INBOARD RIGHT SIDE 9G53131A
1. TAILBOOM 4. RIGHT SIDE THRUSTER EXTENSION FAIRING

2. RIGHT SIDE UPPER TAILBOOM/THRUSTER FAIRING 5. VORTEX GENERATOR
3. LOWER TAILBOOM/THRUSTER FAIRING
Figure 205. Vortex Generator Locations
Page 212
7. Vortex Generator
CAUTION
A. Vortex Generator Removal Do not sand into or expose composite fi
bers.
(Ref. Figure 205) Do not use aluminum oxide abrasives on
graphite/epoxy materials.
(1). Apply masking tape around vortex
generator to be removed. (2). Remove surface gloss with scouring pad
(C817) or 180 grit or finer sandpaper.
(2). Remove paint at edge of vortex genera
tor (ref. CSP-SPM, Section 20-40-00, Solvent Cleaner (C429)
Paint Removal Mechanical)
(3). Attach a thermometer next to vortex

generator.
(3). Clean residue from sanded area with
(4). Heat vortex generator to 1505F (665C). solvent cleaner (C429).
(4). Remove surface gloss from the bottom
(5). Remove vortex generator with a plastic of the vortex generator with scouring
chisel. pad (C817) or 180 grit or finer sandpa
per.
CAUTION Solvent Cleaner (C429)
Do not sand into or expose composite fi
bers.
Do not use aluminum oxide abrasives on
graphite/epoxy materials. (5). Wipe bottom of the vortex generator
with solvent cleaner (C429).
(6). Remove excess epoxy with 180 grit or
finer sandpaper. Activator (C441)
B. Vortex Generator Installation
(Ref. Figure 205)

(6). Apply activator (C441) to the attach
surface and the vortex generator
Consumable Materials bottom (Ref. manufacturer's instruc
(Ref. CSPSPM) tions).
Item Nomenclature
NOTE: Top row of vortex generators on fairings
C817 Pad, Scouring, Cellulose/Nylon and tailboom have end with angle pointed
C429 Solvent Cleaner down. Bottom row of vortex generators on
C440 Adhesive, Acrylic fairings have end with angle pointed up.
C441 Activator Adhesive, Acrylic (C440)
(1). Apply masking tape to the surface

where the vortex generator will be (7). Apply adhesive (C440) to the bottom of
installed. Apply tape with 0.020 inch the vortex generator and immediately
(0.51 mm) clearance around the vortex install the vortex generator (ref.
generator. manufacturer's instructions).
Page 213
(8). Immediately remove unwanted adhe (10). Remove masking tape

sive around vortex generator with
wooden end of a cotton swab or equiva
lent.
(9). Check for voids between vortex genera
tor and attach surface. If there are
voids, do the steps that follow:
(a). If it is less than fifteen minutes since
application of activator, fill void with (11). Remove unwanted adhesive with
more adhesive (ref. manufacturer's isopropyl alcohol (C419).
instructions).
(12). Let adhesive (C440) cure (ref. manufac
(b). If it is more than fifteen minutes
turer's instructions.
since application of activator, apply
activator and then fill void with more
adhesive (ref. manufacturer's instruc (13). If necessary, touch-up paint (ref.
tions) CSP-SPM).
1 (10 PL) 3
2 (10 PL)
9G53-132
1. BOLT 3. THRUSTER EXTENSION

2. WASHER
Figure 206. Thruster Extension
Page 214
8. Thruster Extension B. Thruster Extension Installation
A. Thruster Extension Removal (Ref. Figure 206)

(1). Prepare mating surfaces of tailboom
(Ref. Figure 206) and thruster extension at the 1 o'clock
and 11 o'clock positions 0.62 inch (15.8
(1). Remove Access Panel S2. mm) diameter for Class L electrical
bond (ref. CSP-SPM).
(2). Remove access panels SL1 and SR1.
(2). Install bolts and washers attaching
(3). Remove access panels SL8 and SR8. thruster extension to tailboom. Torque
bolts.
(4). Remove thruster assembly (ref. Section (3). Test thruster extension for Class L
67-20-00).
electrical bond (ref. CSP-SPM).
Support thruster extension (4). Install thruster assembly (ref. Section
CAUTION when removing bolts. 67-20-00).
(5). Remove bolts (1) and washers (2). (5). Install access panels SL8 and SR8.
(6). Install access panels SL1 and SR1.
(6). Remove thruster extension (3) from
tailboom (7). Install Access Panel S2.
Page 215
11
1
2 (16 PL)
10
REF. 1
3
2 (16 PL)
9
8 REF. 2
6 REF. 2
5 4
VIEW LOOKING
FORWARD
UPPER VANE SHOWN

LOWER VANE TYPICAL
9G53133
1. TAILBOOM 7. AFT COAXIAL COVER

2. SLOT VANE 8. FORWARD COAXIAL COVER
3. UPPER AIRFOIL 9. LOWER INLET RAMP
4. SLAT ASSEMBLY 10. UPPER INLET RAMP
5. LOWER AIRFOIL 11. AFT WIRING COVER
6. SEALING COMPOUND
Figure 207. Tailboom Secondary Details
Page 216
9. Tailboom Slot Vane NOTE: This task is typical for upper and lower
slot vane installation.
A. Tailboom Slot Vane Removal
(Ref. Figure 207) Alcohol, Isopropyl (C419)
(Ref. CSPSPM)
Item Nomenclature
(1). Clean surface of slot vane and attach
surfaces with isopropyl alcohol (C419).
NOTE: This task is typical for upper and lower
slot vane removal. Do not use cotton or wool
WARNING cloth with cyanoacrylate
(1). Remove thruster extension.
adhesive. Cotton or wool can cause a
Do not use sharp tools when re strong reaction with cyanoacrylate
CAUTION moving slot vane. adhesive, which can cause a fire.
(2). Remove sealing compound (6) from
edges of slot vane (2). Remove slot Adhesive, Cyanoacrylate (C442)
vane.
(2). Apply cyanoacrylate adhesive (C442) to

slot vane at two places on each edge.
(3). Clean sealing compound from upper
airfoil (3) and slat assembly (4) or slat (3). Install slot vane.
assembly (4) and lower airfoil (5) with
isopropyl alcohol (C419).
B. Tailboom Slot Vane Installation
(Ref. Figure 207)
(Ref. CSPSPM) (4). Seal accessible edges of slot vane with
Item Nomenclature sealing compound (C234). Maximum
C419 Alcohol, Isopropyl sealing compound width 0.12 inch (3.0
C234 Sealing Compound mm).
C442 Adhesive, Cyanoacrylate
(5). Install thruster extension.
Page 217
10. Tailboom Inlet Ramp NOTE: This task is typical for upper and lower
inlet ramp installation.
A. Tailboom Inlet Ramp Removal
(Ref. Figure 207) Alcohol, Isopropyl (C419)
(Ref. CSPSPM)
Item Nomenclature
C419 Alcohol, Isopropyl (1). Wipe inlet ramp and tailboom with
NOTE: This task is typical for upper and lower
inlet ramp removal.
NOTE: Align inlet ramp to match contour of
tailboom surface. Maximum incorrect align
(1). Remove tailboom. ment 0.10 inch (2.5 mm).
Do not damage inner surface of Adhesive (C426)
CAUTION tailboom.
(2). Cut inlet ramp (9) or (10) from tailboom
(1).
CAUTION (2). Mix adhesive (C426), refer to manufac

Do not sand into or expose composite fi turer's instructions.
bers.
NOTE: The thickness of the adhesive must be
Do not use aluminum oxide abrasives on 0.002 to 0.040 inch (0.05 to 1.02 mm).
(3). Remove excess epoxy, with 180 grit or (3). Bond inlet ramp to inner surface of
finer sandpaper. tailboom with adhesive (C426).
Alcohol, Isopropyl (C419) (4). Allow adhesive (C426) to cure, refer to

manufacturer's instructions.

B. Tailboom Inlet Ramp Installation
(Ref. Figure 207) (5). Mix epoxy adhesive (C405), refer to
(6). Fill and fair inlet ramp with epoxy
(Ref. CSPSPM)
adhesive (C405).
Item Nomenclature
C419 Alcohol, Isopropyl (7). Allow epoxy adhesive (C405) to cure,
C426 Adhesive refer to manufacturer' instructions.
(8). Install tailboom.
Page 218
11. Tailboom Coaxial Cover Alcohol, Isopropyl (C419)

A. Tailboom Forward Coaxial Cover
Removal
(Ref. Figure 207)
Consumable Materials (2). Wipe froward coaxial cover and tail

(Ref. CSPSPM) boom with isopropyl alcohol (C419).
Item Nomenclature
Adhesive (C426)
(1). Remove tailboom lower inlet ramp.
Do not damage inner surface of
CAUTION tailboom.
(2). Cut forward coaxial cover (8) from
tailboom (1). (3). Mix adhesive (C426), refer to manufac
CAUTION
Do not sand into or expose composite fi NOTE: The thickness of the adhesive must be
bers. 0.002 to 0.040 inch (0.05 to 1.02 mm).
graphite/epoxy materials. (4). Bond froward coaxial cover to inner
(3). Remove excess epoxy, with 180 grit or surface of tailboom with adhesive
finer sandpaper. (C426).

(5). Allow adhesive (C426) to cure, refer to

B. Tailboom Forward Coaxial Cover
Installation
(Ref. Figure 207)
(6). Mix epoxy adhesive (C405), refer to
Consumable Materials manufacturer's instructions.
(Ref. CSPSPM)
Item Nomenclature
(7). Fill and fair forward coaxial cover with
C419 Alcohol, Isopropyl epoxy adhesive (C405).
C426 Adhesive
(8). Allow epoxy adhesive (C405) to cure,
refer to manufacturer' instructions.
(1). Trim forward flange of forward coaxial
cover to fit flush within 0.030 inch
(0.76 mm) of forward edge of tailboom. (9). Install tailboom lower inlet ramp.
Page 219
C. Tailboom Aft Coaxial Cover Removal Alcohol, Isopropyl (C419)
(Ref. Figure 207)
(1). Wipe aft coaxial cover and tailboom
(Ref. CSPSPM)
with isopropyl alcohol (C419).
Item Nomenclature
C419 Alcohol, Isopropyl Adhesive (C426)
(1). Remove thruster extension.
Do not damage inner surface of (2). Mix adhesive (C426), refer to manufac
CAUTION tailboom. turer's instructions.
(2). Cut aft coaxial cover (7) from tailboom NOTE: The thickness of the adhesive must be
(1). 0.002 to 0.040 inch (0.05 to 1.02 mm).
(3). Bond aft coaxial cover to inner surface
CAUTION of tailboom with adhesive (C426).
(4). Allow adhesive (C426) to cure, refer to
Do not sand into or expose composite fi manufacturer's instructions.
bers.
(3). Remove excess epoxy, with 180 grit or

finer sandpaper.
(5). Mix epoxy adhesive (C405), refer to
Alcohol, Isopropyl (C419) manufacturer's instructions.
(6). Fill and fair aft coaxial cover with
epoxy adhesive (C405).
isopropyl alcohol (C419). (8). Install thruster extension.
E. Tailboom Aft Wiring Cover Removal
D. Tailboom Aft Coaxial Cover Installation
(Ref. Figure 207)
(Ref. Figure 207)
Consumable Materials (Ref. CSPSPM)
(Ref. CSPSPM) Item Nomenclature
Item Nomenclature C419 Alcohol, Isopropyl
C426 Adhesive (1). Remove thruster extension.
C405 Adhesive, Epoxy Do not damage inner surface of
CAUTION tailboom.
NOTE: Align aft coaxial cover forward end to (2). Cut aft wiring cover (11) from tailboom
match contour of mating airfoils. (1).
Page 220

CAUTION
Do not sand into or expose composite fi

bers.
Do not use aluminum oxide abrasives on (1). Wipe aft wiring cover and tailboom
graphite/epoxy materials. with isopropyl alcohol (C419).
Adhesive (C426)
(3). Remove excess epoxy, with 180 grit or
finer sandpaper.

(2). Mix adhesive (C426), refer to manufac
NOTE: The thickness of the adhesive must be
0.002 to 0.040 inch (0.05 to 1.02 mm).
(4). Clean residue from sanded area with (3). Bond aft wiring cover to inner surface
isopropyl alcohol (C419). of tailboom with adhesive (C426).
F. Tailboom Aft Wiring Cover Installation (4). Allow adhesive (C426) to cure, refer to
(Ref. Figure 207) Adhesive, Epoxy (C405)
(Ref. CSPSPM)
Item Nomenclature (5). Mix epoxy adhesive (C405), refer to
C419 Alcohol, Isopropyl manufacturer's instructions.
C426 Adhesive (6). Fill and fair aft wiring cover with epoxy
C405 Adhesive, Epoxy adhesive (C405).
NOTE: Align aft wiring cover forward end to
match contour of mating airfoils. (8). Install thruster extension.
Page 221
Page 222
Section
535500
Empennage
EMPENNAGE
1. Empennage General between the empennage attach frames. The
panel gives access to the inner side of the spar
(Ref. Figure 1) during the installation of the inboard ribs and
The empennage has the components that empennage attach fittings. The empennage
follow: horizontal stabilizer, elastomeric wire harnesses come out through this panel.
damper, left and right, upper and lower The panel is made from aluminum alloy sheet.
endplates, and fairings. The panel is installed with blind titanium
fasteners.
2. Horizontal Stabilizer
C. Inboard and Outboard Rib
(Ref. Figure 1)
The inboard and outboard ribs are installed
The horizontal stabilizer is a control surface longitudinally against the inner surfaces of the
that does not move. It gives pitch stability to horizontal stabilizer spar. The left and right
the helicopter in forward flight. inboard ribs give support to the empennage
The horizontal stabilizer is attached to two attach frames. The left and right outboard ribs
frames on the aft end of the tailboom. On the give support to the upper and lower journal
right side, the horizontal stabilizer is attached (bearing) housings.
to the frames by bolts that permit the stabiliz The left and right inboard ribs are machined
er to pivot. On the left side, the horizontal from aluminum alloy plate. The ribs are
stabilizer is attached to an elastomeric damper installed with blind titanium fasteners.
that decreases vibration into the empennage
attach frames. The left and right outboard ribs are made of
monolithic laminates with multiple plies of
The horizontal stabilizer has the components graphite/epoxy. The ribs are installed with
that follow: horizontal stabilizer bonded blind titanium fasteners.
assembly, lower structural skin panel, inboard
and outboard ribs, empennage attach fittings D. Empennage Attach Fitting and Intercostal
and intercostals, journal (bearing) housings,
journal bearings, attach brackets, and access The empennage attach fittings and intercos
tals attach the horizontal stabilizer to the
covers.
attach frames on the aft end or the tailboom.
A. Horizontal Stabilizer Bonded Assembly The left and right empennage attach fittings
are installed against the external side of the
The horizontal stabilizer bonded assembly has horizontal stabilizer spar. The forward and aft
the components that follow: spar, trailing edge intercostals are installed between the forward
core, and trailing edge skin. and aft empennage attach frames, and to the
horizontal stabilizer spar. The attach fittings
The spar and trailing edge skin are made as and intercostals are installed with blind
monolithic laminates of graphite/epoxy. The titanium fasteners and/or rivets.
spar has an external surface ply of Astro
strike
aluminum mesh on the lower surface The left and right empennage attach frames
and Astrostrike
and aluminum foil on the are machined from aluminum alloy plate. The
upper surface. The Astrostrike
and alumi forward and aft intercostals are made from
num foil give lightning strike protection and a aluminum alloy sheet.
ground for antenna installations. The trailing
edge core is machined nomex honeycomb. E. Journal Housings and Journal Bearings
B. Lower Structural Skin Panel The journal housings and journal bearings
give support for the left and right endplate
The lower structural skin panel is installed on spar tubes. The left and right upper and lower
the bottom of the horizontal stabilizer spar journal housings are installed at the outboard
Page 1
ends of the horizontal stabilizer spar. Each and lower endplates are installed on a spar
journal housing has an integral attach flange tube that is controlled by the Vertical Stabiliz
and is installed with blind titanium fasteners. er Control System (VSCS), for more data about
The journal bearings are installed into the the VSCS system, refer to Section 67-00-00.
journal housings with an interference fit.
The left and right upper and lower endplates
The left and right upper and lower journal
are installed on the spar tubes and are
housings are machined from aluminum alloy
different at each location. The upper endplates
plate. The journal bearings have an aluminum
have different trailing edge tabs. Only the
alloy outer housing and a flanged Karon
right lower endplate has a trailing edge tab.

inner liner.
The edplates are also installed at different
F. Attach Bracket angles.
The attach brackets are installed to the inner The endplates are installed on the spar tubes
side of the horizontal stabilizer spar and give with internal blocks, bolts with lock device,
support for the Vertical Stabilization Control and special nut assemblies. Each endplate has
System (VSCS) actuators, refer to Section an endplate body, upper and lower blocks,
67-20-00 for more date about the VSCS closeouts, and tip cap.
system. The attach brackets are installed with
blind titanium fasteners.
A. Endplate Body
The attach brackets are made from aluminum
alloy sheet, and standard hardware. The endplate body is a monolithic laminate
with thicker areas at the leading edge and
3. Elastomeric Damper center sections. The skins are applied on a ply
of syntactic foam at the leading edge and are a
(Ref. Figure 1)
monolithic laminate at the aft section. All
The elastomeric damper attaches the horizon sections and skins are cocured as one assem
tal stabilizer to the left side of the attach bly. All plies in the reinforced sections and the
frames on the aft end of the tailboom. The skins are made of graphite/epoxy. Astrostrike
elastomeric damper inboard side is attached to is installed around the leading edge and ends
the flanges of the attach frames. On the at the spar.
outboard side the elastomeric damper is
attached to the left side attach fitting on the B. Endplate Block
horizontal stabilizer. The elastomeric damper
is attached with bolts and nutplates. The endplate blocks are monolithic laminate
fittings made of multiple plies of fiberglass/
The elastomeric damper has an inboard and
epoxy. The blocks are bonded into the endplate
outboard attach plate connected to a elasto
body with an epoxy adhesive.
meric pad. The damper also has a pin on each
end of the inboard attach plate that engages a
related slot on the outboard attach plate. The C. Closeout
pins and slots keep the damper together if the
elastomeric material comes loose from one of The closeouts are monolithic laminate compo
the two plates. And it is an indication of nents made of multiple plies of graphite/epoxy.
elastomeric pad condition. The attach plates The closeouts are bonded into the endplate
are machined from aluminum alloy stock. The bodies with an epoxy adhesive.
pins are heat treated corrosion resistant steel.
D. Tip Cap
4. Endplate
(Ref. Figure 1) The tip caps are monolithic laminate compo
nents made of multiple plies of resin impreg
The upper and lower endplates are movable nated carbon fiber fabric. The tip caps are
control surfaces that help control yaw of the bonded onto the endplate body with an epoxy
helicopter in forward flight. Each side upper adhesive.
Page 2
E. Trailing Edge Tab board ends of the horizontal stabilizer and fair
the endplates to the horizontal stabilizer. The
The trailing edge tabs installed on the two position lights are also installed on the
upper and on the left lower endplates, are fairings, refer to Section 96-40-00 for more
monolithic laminate components made of data about the position lights. The fairings are
multiple plies of resin impregnated carbon installed with screws and nutplates on the
fiber fabric. The trailing edge tabs are bonded horizontal stabilizer.
onto the trailing edge of the endplate bodies
with an epoxy adhesive.
5. Fairing The fairings are made with multiple plies of
graphite/epoxy and barrier plies of fiberglass/
The forward and aft fairings close the out epoxy.
Page 3
RIGHT SIDE
UPPER ENDPLATE
LEFT SIDE
UPPER ENDPLATE
RIGHT SIDE
RH AFT FAIRING ENDPLATE SPAR TUBE
ACCESS COVER (2 PL)

ACCESS COVER (2 PL) LEFT SIDE
ENDPLATE SPAR TUBE
HORIZONTAL
STABILIZER
RH FORWARD FAIRING
HORIZONTAL TRAILING EDGE TAB
BONDED ASSEMBLY UPPER AND LOWER, LEFT AND RIGHT
LEADING EDGE LH AFT FAIRING

RIGHT SIDE ACCESS COVER
LOWER ENDPLATE
ELASTOMERIC
DAMPER
LH FORWARD FAIRING
LEFT SIDE
LOWER ENDPLATE
RIGHT SIDE
ATTACH FITTING
FORWARD ATTACH
INTERCOSTAL (AFT NOT IN VIEW)
LOWER SKIN PANEL
LH INBOARD
RIB (RH OPPOSITE)
LEFT SIDE
ATTACH FITTING 9G53-040-1
Figure 1. Empennage (Sheet 1 of2)
Page 4
LH UPPER JOURNAL
(BEARING) HOUSING
(RH OPPOSITE)
LH OUTBOARD
RIB (RH OPPOSITE)
JOURNAL BEARING (4 PL)
LH LOWER JOURNAL
(BEARING) HOUSING
(RH OPPOSITE)
CLOSEOUT
TIP CAP
ENDPLATE BODY
TRAILING EDGE TAB

(IF INSTALLED)
AFT CLOSEOUT
ENDPLATE
FORWARD BLOCK (2 PL)
CLOSEOUT
LEFT UPPER ENDPLATE SHOWN
(TYPICAL)
9G53-040-2
Figure 1. Empennage (Sheet 2 of2)
Page 5
Page 6
EMPENNAGE
1. Empennage (2). Connect electrical connectors P310,
P317, and antenna coaxial connector (if
A. Empennage Removal installed.
(Ref. Figure 401) (3). Align empennage left mount with
(1). Remove tailboom/thruster fairings SL1, damper safety pins and right mount
SR1, and S2 (Ref. Section 53-40-00). trunnions with bushings in right side of
attach frames.
(2). Remove nuts (3) and washers (4) and
disconnect bond jumpers (1). (4). Install bolts, shims, washers, and
plastic washers. Use shims to get a
(3). Remove safety wire from bolts (5) and clearance of 0.00-0.002 in. (0.00-0.051
discard. Remove bolts (5), washers (8), mm) between attach frames and
and washers (18). empennage.
(4). Measure and record thickness of (5). Align empennage and damper bolt
washers (18). holes, install bolts and washers. Install
washers between empennage and
(5). Remove safety wire from jam nuts (9) damper to get 0.00-0.010 in
and discard. Remove jam nuts (9) and (0.00-0.254 mm) compression on
washers (11). damper. Torque bolts and safety with
lockwire (C702).
(6). Record location of shims (12) and
plastic washers (13). (6). Install two jam nuts on each bolt.
(7). Put a support below the empennage. Torque inner jam nuts 20-30 in-lb
(2.26-3.39 Nwm). Torque outer jam
(8). Remove bolts (10), washers (11), shims nuts to standard torque. Safety with
(12), and plastic washers (13). lockwire (C702).
(9). Lift empennage up and to the left away (7). Prepare mating surfaces of empennage
from damper safety pins, do not pull on and bond jumper for electrical bond
wire harnesses below empennage. (Ref. CSP-SPM, Section 20-50-00).
(10). Disconnect electrical connectors P310 (8). Install bond jumpers, washers, and
(15), P317 (16), and antenna coaxial nuts. Torque nuts.
connector (if installed) and remove
empennage. (9). Test bond jumpers for Class L
electrical bond (Ref. CSP-SPM, Section
B. Empennage Installation 20-50-00).
(Ref. Figure 401) Sealant, Fuel Resistant (C216)
(Ref. CSPSPM)
Item Nomenclature
C702 Lockwire (10). Environmentally seal bond jumpers,
C216 Sealant, Fuel Resistant use sealant (C216) (Ref. CSP-SPM,
Section 20-50-00).
(1). Put empennage above attach frames (11). Install tailboom/thruster fairings SL1,
and put a support below it. SR1, and S2 (Ref. Section 53-40-00).
Page 401
2. Elastomeric Damper (3). Remove bolts (14), washers(8), and

damper (7).
A. Elastomeric Damper Removal
B. Elastomeric Damper Installation
(1). Install damper, bolts, and washers.
(1). Remove empennage.
Torque bolts and safety with lockwire
(C702).
(2). Remove lockwire from bolts (14) and
discard. (2). Install empennage.
Page 402
17 6
2
16
7
15
7 REF
18 (4 PL)
11 10
LOOKING AFT
1 (2 PL)
11
9 (2 PL)
4 (2 PL)
3 (2 PL)
12
11
13
14 (4 PL)
12 13
8 (4 PL)
5 (4 PL)
FWD MOUNT SHOWN 7
AFT MOUNT OPPOSITE
8 (4 PL)
2
9G53-001B
1. BOND JUMPER 10. BOLT
2. FORWARD ATTACH FRAME 11. WASHER
3. NUT 12. SHIM
4. WASHER 13. PLASTIC WASHER
5. BOLT 14. BOLT
6. EMPENNAGE 15. ELECTRICAL CONNECTOR (P310)
7. ELASTOMERIC DAMPER 16. ELECTRICAL CONNECTOR (P317)
8. WASHER 17. AFT ATTACH FRAME
9. JAM NUT 18. WASHER
Figure 401. Empennage
Page 403
3. Stabilizer Outboard Fairing (SR3,SL3) B. Stabilizer Outboard Fairing (SR3,SL3)

(Stabilizer) Installation
A. Stabilizer Outboard Fairing (SR3,SL3) (Ref. Figure 402)
Removal
(Ref. Figure 402) NOTE: Installation of left and right outboard
fairings is typical.
NOTE: Removal of left and right outboard fai
rings is typical. (1). Install aft fairing, screws, and washers.
Torque screws.
(2). Install bond jumper, clamp, screw,
(2). Remove forward fairing (1) and aft washers, and nut. Torque nut.
fairing (9).
(3). Disconnect wires from position light (3). (3). Connect wires to position light.
(4). Remove screw (5), washers (6), nut (7), (4). Install forward fairing, screws, and
clamp (8), and bond jumper (4). washers. Torque screws.
10 (11 PL )
11 ( 11 PL )
RH SIDE
5
2
6 (2 PL)
8
7
4 9
LH SIDE
3
11 (13 PL)
1
10 (13 PL )
9G53-006
1. FORWARD FAIRING 7. NUT
2. HORIZONTAL STABILIZER 8. CLAMP
3. POSITION LIGHT 9. AFT FAIRING
4. BOND JUMPER 10. SCREW
5. SCREW 11. WASHER
6. WASHER
Figure 402. Stabilizer Outboard Fairing
Page 404
4. Upper and Lower Horizontal Endplates (3). Make sure the bolt holes of the end
(Vertical Stabilizer) plates are out-of-round.
B. Endplate Installation
A. Endplate Removal
(Ref. Figure 403)
(Ref. Figure 403)
NOTE: This task is typical for the left and
right, upper and lower, endplate installa
NOTE: This task is typical for the left and tion.
right, upper and lower, endplate removal.
(Ref. CSPSPM)
Item Nomenclature
3
C228 Sealant Primer
1 (2 PL) C429 Solvent Cleaner
2 (2 PL)
(1). Prepare surface of endplate, 1.062 inch

(26.98 mm) dimension around attach
hole for electrical bond (ref. CSP-SPM,
Section 20-50-00).
5
1 (2 PL) (2). Clean threads of endplate attach nuts

2 (2 PL)
in endplate spar tube and attach bolts
with solvent cleaner (C429).
Sealant Primer (C228)

NOTE: LH SIDE SHOWN, RH SIDE OPPOSITE
9G53-055A
1. BOLT
2. WASHER
3. UPPER HORIZONTAL ENDPLATE (VERTICAL (3). Apply sealant primer (C228) to threads
STABILIZER)
4. LOWER HORIZONTAL ENDPLATE (VERTICAL
of bolts (refer to manufacturer instruc
STABILIZER) tions).
5. ENDPLATE SPAR TUBE
Figure 403. Horizontal Endplates (Vertical
Stabilizer)

(C226) to threads of bolts (1) (ref.
(2). Remove endplate (3 or 4). manufacturer instructions).
Page 405
Be careful when you install (5). Make sure lock devices in endplate
WARNING endplates. It is possible to attach bolts (1) are serviceable (ref.
install endplates in an incorrect posi CSP-SPM, Section 20-10-00)
tion. This can cause the helicopter to
be less stable in the directional control (6). Put endplates (3, 4) in their installed
azimuth. positions with washers (2) and bolts (1).
Bolts that attach lower end (a). Torque bolts 9 to 17 in-lb (1.02 to
CAUTION plates are longer than bolts that 1.92 Nm) (ref. CSP-SPM, Section
attach upper endplates. 20-10-00).
(7). Test washers (2) for Class L electrical
NOTE:
bond (ref. CSP-SPM, Section
When you install upper right or upper left 20-50-00).
endplate, make sure tab on trailing edge
of endplate is pointed outboard. Sealant, Fuel Resistant (C216)
When you install lower right endplate,
make sure tab on trailing edge of end
plate is pointed inboard.
Lower left endplate does not have a trail (8). Environmentally seal washers (2) and
ing edge tab. bolt (1) heads to endplates (3, 4) with
Bolts (1) that attach endplates have a sealant (C216) (ref. CSP-SPM, Section
lock device. 20-50-00).
Page 406
EMPENNAGE
INSPECTION / TEST
1. Empennage (a). Remove remaining sealant.
A. Empennage Inspection (Area 7) (b). Remove bolt, make sure lock device is
serviceable (ref. CSP-SPM, Section
(Ref. Figure 401) 20-10-00).
(1). Examine skin for cracks, bond separa (c). Install bolt and environmentally seal
tion, and damage. None permitted. (ref. Endplate Installation).
(2). Examine attach fitting for damage and C. Endplate Spar Tube Inspection (Area 7)
loose or missing attach hardware. None (Ref. Section 67-20-00)
permitted.
D. Elastomeric Damper Condition Test
(3). Examine access panels, nutplate (Ref. Figure 602)
fasteners, and position lights for
damage. None permitted. NOTE: Do test at 55 to 91F (12.78 to
32.78C).
(4). Examine access panel gaskets for
condition and correct installation. No (1). Pull left side of the horizontal down as
damage permitted. far as possible. Check for a minimum
clearance of 0.050 inch (1.27 mm)
(5). Examine endplate torque tubes for between upper left tailboom/thruster
axial end play. Maximum permitted extension fairing edge and horizontal.
0.040 inch (1.016 mm).
(2). Remove upper left tailboom/thruster
(Ref. Figure 601) extension fairing (ref. Section
53-40-00).
NOTE: Measure radial play with a dial indica
(3). Examine forward and aft slots and pins
tor. Make measurement no more than 0.125
for an indication they have touched. If
inch (3.18 mm) from end of journal bear
they have touched, replace damper.
ing, perpendicular to the torque tube. Mea
Record new damper serial number in
sure total play, aft to forward or left to right.
the rotorcraft log book.
(6). Examine endplate torque tubes for NOTE: Do not permanently mark, position can
radial play. Maximum permitted, 0.013 change between inspections.
inch (0.33 mm).
(4). With no load applied to horizontal,
B. Endplate Inspection (Area 7) make a mark aligned with top of
forward pin.
(Ref. Figure 403)
(5). Make another mark 0.22 inch (5.59
(1). Examine skin for cracks, bond separa mm) above the first mark.
tion, and damage. None permitted.
(6). Make another mark 0.34 inch (8.64
(2). Examine for a clearance between mm) above the first mark.
endplate and horizontal stabilizer. NOTE: Put protection on top side of horizontal
(3). Examine endplate attach bolts for stabilizer while you do the steps that follow.
condition of environmental seal and (7). In 5 seconds or less, put 50 lb (22.68
correct installatin. No defects per kg) on top of horizontal stabilizer.
mitted.
(a). Put weight at left outboard end,
(4). If attach bolt is loose or environmental against endplate, and 4 to 6 inch
seal is loose or missing, do the proce (101.6 to 152.4 mm) aft of horizontal
dure that follows: leading edge.
Page 601
(8). After 60 seconds, look at forward pin. (9). Remove the 50 lb (22.68 kg) and
protection from horizontal.
(a). If top of pin is between the 0.22 inch
(5.6 mm) and 0.34 inch (8.6 mm) (10). Install upper left tailboom/thruster
marks, damper is serviceable. fairing (ref. Section 53-40-00).
MEASURE RADIAL PLAY WITH A DIAL

INDICATOR. MAKE MEASUREMENT NO MORE
THAN 0.125 IN. (3.275 mm) FROM END OF
JOURNAL BEARING, PERPENDICULAR TO THE
TORQUE TUBE. MEASURE TOTAL PLAY, AFT
TO FORWARD OR LEFT TO RIGHT. MAXIMUM
PERMITTED PLAY, 0.013 IN. (0.33 mm).
MEASURE RADIAL PLAY WITH A DIAL

INDICATOR. MAKE MEASUREMENT NO MORE
THAN 0.125 IN. (3.275 mm) FROM END OF
JOURNAL BEARING, PERPENDICULAR TO THE
TORQUE TUBE. MEASURE TOTAL PLAY, AFT
TO FORWARD OR LEFT TO RIGHT. MAXIMUM
PERMITTED PLAY, 0.013 IN. (0.33 mm).
9G53-128A
Figure 601. Endplate Spar Tube Bearing Journal Measurement
AREA WHERE PINS CAN

TOUCH AND CAUSE DAMAGE
0.34 INCH (8.64 mm)

0.22 INCH (5.59 mm)
PIN
ELASTROMERIC AFT SLOT

DAMPER
FORWARD SLOT
NO LOAD MARK
9G53-119B
Figure 602. Elastomeric Damper Condition Test
Page 602
EMPENNAGE
REPAIRS
1. Journal Bearing Replacement mately 0.20 inch (5.08 mm) with a
hacksaw blade.
(Ref. Figure 801)
(6). Collapse journal bearing.
Consumable Materials (7). Remove journal bearing from journal
(Ref. CSPSPM) housing, push bearing in.
Item Nomenclature
(8). Clean inner side of journal housing
C205 Sealing Compound with acetone (C436).
C436 Acetone
(9). Examine journal housing for damage
and corrosion.
A. Journal Bearing Removal
(a). No damage or corrosion permitted.
(1). Remove upper and lower endplates (ref.
B. Journal Bearing Installation
Endplate Removal).
NOTE: Journal bearing has an interference fit.
(2). Remove outboard fairing (ref. Stabilizer
Outboard Fairing (SR3, SL3) Removal). (1). Put journal bearing in dry ice, or a
freezer, to become cold at -321_F
(3). Remove spar tube (ref. Section (-1965C) minimum.
67-20-00, Spar Tube Removal).
(2). Heat journal housing with a heat gun
(4). Remove sealing compound from journal below 2505F (1215C) maximum.
bearing.
NOTE: Journal bearing flange must be fully
against journal housing.
CAUTION
(3). Push journal bearing into journal
Do not cut through journal bearing into housing with your hand.
journal housing.
(4). Make sure journal bearing is installed
Journal bearing is approximately 0.250 with flange fully against journal
inch (6.35 mm) thick. housing.
If journal housing is damaged, horizontal
stabilizer must be sent to MDHI for re Sealing Compound (C205)
pair.
NOTE:
Cut through upper journal bearing on for
ward side, to make it easier to collapse (5). Apply sealing compound (C205) all
journal bearing. around journal bearing.
Cut through lower journal bearing on aft (6). Install spar tube (ref. Section
side, to make it easier to collapse journal 67-20-00, Spar Tube Installation).
bearing.
(7). Install outboard fairing (ref. Stabilizer
When you cut journal bearing, stop and Outboard Fairing (SR3, SL3) Installa
measure depth of cut frequently. tion).
(5). Carefully cut a groove the full length of (8). Install upper and lower endplates (ref.
journal bearing to a depth of approxi Endplate Installation).
Page 801
(b). Make spacers with a dimension of

0.125 inch (3.18 mm) and a thick
JOURNAL BEARING CUT UPPER JOURNAL BEARING ness of 0.10 to 0.15 inch (2.5 to 3.8
ON INNER FORWARD SIDE mm)
JOURNAL BEARING
INSTALLED FULLY AGAINST (3). Clean horizontal stabilizer surface in
JOURNAL HOUSING
area where sealing compound gasket
CUT LOWER JOURNAL will be installed with solvent cleaner
BEARING ON INNER AFT SIDE (C429).
(4). Clean access cover inner and outer
surface with solvent cleaner (C429).
(5). Put spacers on access door where
JOURNAL HOUSING
sealing compound gasket will touch and
keep in place with tape.
AFTER INSTALLATION, SEAL ALL

AROUND JOURNAL BEARING
9G53129A (6). Apply release agent (C417) to inner and

outer side of access door and on spacers.
Figure 801. Journal Bearing Replacement (7). Dry release agent (C417) in air for 15
minutes minimum.
2. Access Panel Gaskets (8). Apply another layer of release agent
A. Gasket Repair (C417) to inner and outer side of access
door and on spacers.
(9). Dry release agent (C417) in air for 30
(Ref. CSPSPM)
minutes minimum.
Item Nomenclature Sealing Compound (C234)
C417 Release Agent
(10). Apply a thin layer of sealing compound
NOTE: This repair is typical for all horizontal (C234) adhesion promoter to surface of
stabilizer access panel sealing compound horizontal stabilizer where sealing
gaskets formed at installation. compound gasket will be installed.
(11). Dry sealing compound (C234) adhesion
(1). Remove loose sealing compound from
promoter in air for 30 minutes mini
horizontal stabilizer.
mum.
(2). If necessary, make spacers to keep the (12). Apply sealing compound (C234) to
correct gap between the horizontal surface of horizontal stabilizer.
stabilizer and access panel as follows:
NOTE: Apply sufficient sealing compound to
(a). Make spacers from aluminum sheet more than fill gap between access panel and
or plastic sheet. horizontal stabilizer.
Page 802
(13). Install access panel. (17). Remove unwanted sealing compound

(C234) from around access hole.
(14). Remove unwanted sealing compound
(C234) from around edge of access (18). Apply a light even layer of mica powder,
panel with solvent cleaner (C429). soapstone, or equivalent on full surface
of access panel seal.
(15). Cure sealing compound (C234) in air for (19). Remove tape and spacer(s) from access
14 hours minimum at 205F (-75C) panel.
minimum.
(20). Clean access panel with solvent cleaner
(16). Remove access panel. (C429).
Page 803
Page 804
Chapter
MAIN ROTOR
TABLE OF CONTENTS
62-00-00 Main Rotor System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A

1. Main Rotor System- General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Main Rotor Blade Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
A. Rotor Blade Retention Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
B. Abrasion Strips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
C. Trim Tabs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
D. Electrical Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
3. Pitchcase Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
A. Pitchcase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
B. Centering Bearing/Damper Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
C. Pitch Change Horn Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
4. Main Rotor Hub Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
A. Upper and Lower Hub Halves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
B. Flexbeam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
C. Hub Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
D. Fretting Buffer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
E. Tapered Roller Bearing Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
F. Hub Liner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
G. Drive Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
H. Grounding Brushes and Straps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
I. Droop Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
5. Data Plates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
A. Data Plate Marking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
B. Identification Data Plates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
C. Overhaul Data Plates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Figure 1.Main Rotor System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
6. Upper Flight Controls Subsystem . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
A. Mixer Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
B. Stationary Swashplate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
C. Rotating Swashplate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
D. Scissors Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
E. Pitch Links . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Figure 2.Upper Flight Controls Subsystem . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Fault Isolation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
1. Main Rotor System Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Table 101.Main Rotor System Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Page i

62-10-00 Main Rotor Blade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A

1. Main Rotor Blade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
A. Main Rotor Blade Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
Figure 401.Fragile Area of Rotor Blade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
Figure 402.Removal and Installation of the Main Rotor Blade . . . . . . . . . . . . . . . 402
B. Main Rotor Blade Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 403
Figure 403.Installation of (-101) Blade Retention Bolts . . . . . . . . . . . . . . . . . . . . 404
Figure 404.Installation of (-103) Blade Retention Bolts . . . . . . . . . . . . . . . . . . . . 406
Figure 405.Installation of (-105) Blade Retention Bolt . . . . . . . . . . . . . . . . . . . . . 408
Inspection / Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601
1. Main Rotor Blade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601
A. Main Rotor Blade Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601
B. Main Rotor Blade Abrasion Strip Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601
Figure 601.Main Rotor Blade Inspection (Sheet 1 of 2) . . . . . . . . . . . . . . . . . . . . . 602
C. Main Rotor Blade Trim Tab Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 604
Figure 602.Torque Check for the (-101) Blade Retention Bolts . . . . . . . . . . . . . . 606
2. Blade Retention Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 607
A. Torque Check of the Blade Retention Bolts (PN 900R3100001-101) . . . . . . . . . . 607
B. Force Check of the Blade Retention Bolts (PN 900R3100001-103) . . . . . . . . . . . 609
C. Torque Check of the Blade Retention Bolts (PN 900R3100001-105) . . . . . . . . . . 611
D. Gap Check of the Blade Retention Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 612
Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 801
1. Root Fairing Repair, Main Rotor Blade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 801
A. Main Rotor Blade Root Fairing Filling of Depression or Hole . . . . . . . . . . . . . . . . 801
B. Main Rotor Blade Root Fairing Doubler Installation . . . . . . . . . . . . . . . . . . . . . . . . 802
Figure 801.Blade Root Fairing Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 803
2. Blade Trailing Edge Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 803
Figure 802.Blade Tip Repair (Sheet 1 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 804
3. Abrasion Strip Edge Sealing, Main Rotor Blade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 806
Figure 803.Abrasion Strip Edge Sealing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 806
4. Outboard Abrasion Strip Crack Repair, Main Rotor Blade . . . . . . . . . . . . . . . . . . . . . 807
Figure 804.Outboard Abrasion Strip Crack Repair Area . . . . . . . . . . . . . . . . . . . . 808
62-20-00 Main Rotor Hub Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A
Page ii

A. Main Rotor Hub Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
B. Main Rotor Hub Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
Figure 401.Main Rotor Hub Assembly and Lifting Sling . . . . . . . . . . . . . . . . . . . . 403
2. Main Rotor Hub Damper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 404
A. Main Rotor Hub Damper Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 404
B. Main Rotor Hub Damper Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 404
Table 1.Main Rotor Damper Shim Quantity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 405
3. Main Rotor Centering Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 406
A. Centering Bearing Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 406
B. Centering Bearing Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 406
4. Main Rotor Pitchcase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 406
A. Pitchcase Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 406
B. Pitchcase Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 406
Figure 402.Main Rotor Hub Damper, Feathering Bearing,
and Pitchcase Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 407
5. Droop Stop Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 408
A. Droop Stop Roller Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 408
B. Droop Stop Roller Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 408
Figure 403.Main Rotor Droop Stop Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 408
6. Main Rotor Droop Stop Striker Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 408
A. Striker Plate Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 408
B. Striker Plate Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 409
7. Main Rotor Droop Stop Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 409
A. Droop Stop Support Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 409
B. Droop Stop Support Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 409
8. Main Rotor Grounding Brush . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 410
A. Grounding Brush Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 410
B. Grounding Brush Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 410
9. Main Rotor Grounding Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 410
A. Grounding Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 410
B. Grounding Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 410
10. Drive Ring Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 410
A. Drive Ring Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 410
B. Drive Ring Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 410
Figure 404.Main Rotor Hub Droop Stop and Grounding Brush Installation . . . 411
11. Hub Plate, Main Rotor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 411
12. Lower Hub, Main Rotor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 411
Page iii

Figure 405.Main Rotor Hub Flexbeam Installation . . . . . . . . . . . . . . . . . . . . . . . . . 412
13. Flexbeam, Main Rotor Hub . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 413
A. Flexbeam Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 413
B. Flexbeam Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 413
14. Lead/Lag Leg Wear Shim, Main Rotor Hub . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 414
A. Lead/Lag Leg Wear Shim Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 414
B. Lead/Lag Leg Wear Shim Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 414
Figure 406. Bearing and Seal Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . . 416
15. Upper Hub Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 417
A. Upper Hub Buildup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 417
16. Upper Seal, Upper Hub Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 417
A. Upper Seal Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 417
B. Upper Seal Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 417
17. Upper Bearing, Upper Hub Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 417
A. Upper Bearing Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 417
B. Upper Bearing Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 418
18. Shim, Upper Hub Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 418
19. Lower Seal, Upper Hub Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 418
A. Lower Seal Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 418
B. Lower Seal Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 418
20. Liner, Main Rotor Hub . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 419
21. Lower Bearing, Upper Hub Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 419
A. Lower Bearing Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 419
B. Lower Bearing Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 419
22. Upper Bearing Cup (Outer Race), Upper Hub Assembly . . . . . . . . . . . . . . . . . . . . . . . 420
A. Upper Bearing Cup Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 420
B. Upper Bearing Cup Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 420
23. Center Seal, Upper Hub Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 421
A. Center Seal Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 421
B. Center Seal Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 421
24. Lower Bearing Cup (Outer Race), Upper Hub Assembly . . . . . . . . . . . . . . . . . . . . . . . 421
A. Lower Bearing Cup Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 421
B. Lower Bearing Cup Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 421
25. Bearing Shim Selection, Upper Hub Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 422
26. Identification Plate,Upper Hub Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 424
Figure 407.Upper Hub Bearing Preload Pull Direction and Hub Identification 424
A. Identification Plate Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 424
Page iv

27. Balance Weight, Hub/Pitchcase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 424
A. Balance Weight Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 424
B. Balance Weight Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 424
Figure 408.Pitch Horn Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 425
28. Pitch Horn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 425
A. Pitch Horn Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 425
B. Pitch Horn Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 425
Inspection/Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601
A. Main Rotor Hub Assembly Inspection (Area 4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601
B. Identification/Data Plate Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 602
Figure 601.Main Rotor Hub Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 603
C. Flexbeam Inspection (Area 4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 604
Figure 602.Flexbeam Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 605
D. Upper Seal Inspection (Area 4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 607
E. Upper Bearing Inspection (Area 4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 607
F. Lower Seal Inspection (Area 4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 608
G. Lower Bearing Inspection (Area 4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 608
H. Center Seal Inspection (Area 4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 609
I. Lead/Lag Leg Shim Inspection (Area 4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 609
Figure 603.Main Rotor Hub Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 610
2. Main Rotor Hub Special Inspections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 611
A. Main Rotor Upper Hub Web Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 611
B. Main Rotor Upper Hub Flange Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 611
Figure 604.Main Rotor Upper Hub Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 611
Figure 605.100-Hour Main Rotor Hub and 50-Hour
Centering Bearing Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 612
C. 100-Hour Inspection of the Main Rotor Hub Assembly . . . . . . . . . . . . . . . . . . . . . . 613
D. 50-Hour Inspection for the Center Bearing Assemblies . . . . . . . . . . . . . . . . . . . . . 614
Figure 606.Main Rotor Upper Hub Eddy Current Inspection . . . . . . . . . . . . . . . . 616
E. Main Rotor Upper Hub Eddy Current Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . 617
3. Main Rotor Hub Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 618
A. Main Rotor Hub Droop Angle Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 618
Figure 607.Droop Angle Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 618
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 801
1. Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 801
A. Hub Small Nick and Scratch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 801
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B. Upper Hub Upper Surface Corrosion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 801
Figure 801.Main Rotor Hub Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 802
Figure 802.Flexbeam Pockets, Hub Mating Surfaces, and Hub Plate . . . . . . . . 802
C. Flexbeam Pockets and Hub Mating Surfaces Corrosion . . . . . . . . . . . . . . . . . . . . . 803
D. Hub Plate Corrosion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 803
Figure 803.Flexbeam Bumper Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 804
2. Repairs for the Flexbeam-Bumper Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 805
A. Flexbeam Bumper Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 805
Figure 804.Flexbeam Fissure Fill and Nick Repair . . . . . . . . . . . . . . . . . . . . . . . . . 806
B. Flexbeam Fissure Fill . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 806
C. Flexbeam Nick Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 807
Figure 805.Main Rotor Hub Configuration Change . . . . . . . . . . . . . . . . . . . . . . . . . 808
3. Modification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 808
A. Main Rotor Hub Configuration Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 808
Table 801.Main Rotor Hub Configuration Change . . . . . . . . . . . . . . . . . . . . . . . . . . 809
62-30-00 Swashplate and Mixer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A
1. Pitch Link Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
A. Pitch Link Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
B. Pitch Link Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
Figure 401.Pitch Link Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 402
2. Scissors Drive Link Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 402
A. Scissors Drive Link Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 402
B. Scissors Drive Link Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 402
3. Scissors Lower Drive Link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 402
A. Scissors Lower Drive Link Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 402
B. Scissors Lower Drive Link Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 402
Figure 402.Scissors Drive Link Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 403
4. Lateral Anti-Torque Drive Link Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 404
A. Lateral Anti-Torque Drive Link Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . 404
B. Lateral Anti-Torque Drive Link Assembly Installation . . . . . . . . . . . . . . . . . . . . . 404
5. Longitudinal Drive Link Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 404
A. Longitudinal Drive Link Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 404
B. Longitudinal Drive Link Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 404
Figure 403.Lateral and Longitudinal Link Assembly . . . . . . . . . . . . . . . . . . . . . . . 405
6. Non-Adjustable Collective Drive Link Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 405
A. Non-Adjustable Collective Drive Link Assembly Removal . . . . . . . . . . . . . . . . . . . 405
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B. Non-Adjustable Collective Drive Link Assembly Installation . . . . . . . . . . . . . . . . 406
7. Adjustable Collective Drive Link Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 406
A. Adjustable Collective Drive Link Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . 406
B. Adjustable Collective Drive Link Assembly Installation . . . . . . . . . . . . . . . . . . . . . 406
Figure 404.Non-adjustable and Adjustable Collective Link . . . . . . . . . . . . . . . . . 407
8. Mixer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 408
A. Mixer Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 408
B. Mixer Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 408
9. Lateral Mixer Bellcrank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 408
A. Lateral Mixer Bellcrank Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 408
B. Lateral Mixer Bellcrank Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 408
10. Longitudinal Mixer Bellcrank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 409
A. Longitudinal Mixer Bellcrank Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 409
B. Longitudinal Mixer Bellcrank Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 409
11. Collective Mixer Bellcrank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 409
A. Collective Mixer Bellcrank Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 409
B. Collective Mixer Bellcrank Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 409
Figure 405.Mixer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 410
12. Swashplate Azimuth Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 411
A. Swashplate Azimuth Sensor Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 411
B. Swashplate Azimuth Sensor Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 411
Figure 406.Swashplate Azimuth Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 411
13. Swashplate Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 412
A. Swashplate Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 412
B. Swashplate Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 412
14. Swashplate Bearing Retainer Rings and Labyrinth Seals . . . . . . . . . . . . . . . . . . . . . 412
A. Retainer Rings and Seals Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 412
Figure 407.Retainer Rings and Seals Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 412
B. EARLY CONFIG - Retainer Rings and Seals Installation
(One Piece Retainer Ring) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 413
Figure 408.EARLY CONFIG - Swashplate Bearing Preload Measurement
(One Piece Retainer Rings Installation) . . . . . . . . . . . . . . . . . . . . . . . . . 414
C. CURRENT CONFIG - Retainer Rings and Seals Installation
(Two Piece Retainer Ring) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 414
Figure 409.CURRENT CONFIG - Swashplate Retainer Rings Installation
(Two Piece Retainers) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 415
15. Non-Rotating Swashplate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 415
A. Non-Rotating Swashplate Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 415
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B. Non-Rotating Swashplate Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 416
Figure 410.Non-Rotating Swashplate Installation . . . . . . . . . . . . . . . . . . . . . . . . . 416
16. Swashplate Spherical Slider Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 417
A. Swashplate Spherical Slider Bearing Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 417
B. Swashplate Spherical Slider Bearing Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 417
Figure 411.Swashplate Spherical Slider Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . 418
C. Swashplate Angular Contact Ball Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 418
D. Swashplate Ball Bearing Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 418
E. Swashplate Ball Bearing Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 418
Figure 412.Swashplate Ball Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 419
Inspection/Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601
1. Swashplate Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601
A. Swashplate Assembly Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601
B. Swashplate Assembly Upper Bearing Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . 601
Figure 601.Swashplate Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 602
C. Swashplate Drive Link Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 603
Figure 602.Swashplate Drive Link Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 603
2. Mixer Assembly Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 604
Figure 603.Lateral Mixer Bellcrank And Lateral Anti-Torque Drive Link . . . . 604
3. Pitch Link Inspection (Area 4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 605
Figure 604.Pitch Links . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 605
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 801
1. Pitch Link Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 801
A. Pitch Link Bearing Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 801
B. Pitch Link Bearing Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 801
Figure 801.Pitch Link Bearing Removal and Bore Inspection . . . . . . . . . . . . . . . 802
C. Pitch Link Bearing Staking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 802
Figure 802.Bearing Staking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 803
D. Pitch Link Bearing Proof Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 803
Figure 803.Proof-Load Verification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 804
2. Scissors Assembly Drive Link Repair (-107) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 804
A. Upper Drive Link Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 804
B. Lower Drive Link Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 805
Figure 804.Scissors Drive Link Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 806
C. Upper Drive Link Flanged Bearing Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 806
D. Upper Drive Link Flanged Bearing Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 806
Figure 805.Upper Drive Link Flanged Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 807
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E. Lower Drive Link Flanged Bearing Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 808
F. Lower Drive Link Flanged Bearing Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 808
Figure 806.Lower Drive Link Flanged Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 809
3. Drive Link Attach Bearing Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 810
A. Drive Link Attach Bearing Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 810
B. Drive Link Attach Bearing Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 810
Figure 807.Drive Link Attach Bearing Flange Removal . . . . . . . . . . . . . . . . . . . . 811
Page ix

Page x
Section
620000
Main Rotor System
MAIN ROTOR SYSTEM

1. Main Rotor System General C. Trim Tabs
(Ref. Figure 1) Trim tabs are located on the trailing edge of
each rotor blade. The trim tabs are bent up or
The main rotor system is mounted on the static down to track the rotor blades.
support mast and driven by the main rotor drive
shaft. The main rotor system provides the lift, D. Electrical Grounding
and by control input, lateral, longitudinal, and An embedded metallic mesh (Astrostrike
) in
collective control. The main rotor system the blade skin electrically connects the abrasion
consists of the main rotor blades, pitchcase strips with grounding lugs located near the root
assemblies and main rotor hub assembly. of the blade. Bonding jumpers connect these
lugs to similar lugs in the pitchcase. This
2. Main Rotor Blade Assembly electrical path reduces, or eliminates, damage
caused by lightning, and provides for static
The main rotor blade assembly is attached to discharge from the rotor blade.
the main rotor hub by the flexbeam and blade
retention bolts. Main rotor blades are 3. Pitchcase Assembly
constructed of fiberglass using bonded
pre-cured spars and skins. Behind the spar The pitchcase assembly is attached to the root
the blade is filled with a honeycomb core. of the rotor blade by the retention bolts and
connected to the hub by the flexbeam. At
Each blade spans 154.88 inches with a chord tached to the hub end of the pitchcase is the
of 10.0 inches. The blades are twisted from pitch change horn.
+10 degrees, at the root, to +4.5 degrees, 21.38
The pitchcase assembly includes:
inches from the root. The twist is then linear
to -2.5 degrees at the tip. Twist helps to A. Pitchcase
equalize lift along the span of the main rotor
blade. A thinner airfoil section near the tip of The pitchcase is torsionally rigid to transfer
the blade is used to reduce the effects of air control input to the rotor blade. Pitchcases are
compressibility at high speeds. a composite structure made of filament wound
graphite, with imbedded Astrostrike
for
The main rotor blade installation includes: electrical grounding.
A. Rotor Blade Retention Bolts B. Centering Bearing/Damper Assembly

The centering bearing and damper assembly
Rotor blade retention bolts are high torque bolts are installed at the hub end of the pitchcase.
with expandable bushings. They attach the The centering bearing fits onto a snubber bolt
rotor blades to the pitchcase and flexbeam. With in the lower hub half and provides a fixed
the bolt inserted and torqued, the expansion feathering axis for the rotor blade. The
bushings create an interference fit installation centering bearing is captured between an
to lock the bolt in place. The rotor blade upper and lower elastomeric damper assembly
retention bolt creates a positive alignment of the that help the flexbeam dampen out the
pitchcase, flexbeam, and rotor blade. lead/lag motion of the rotor blade. Dampers
B. Abrasion Strips are retained to the pitchcase by upper and
lower bolted retainer caps.
Two metal abrasion strips are bonded to the C. Pitch Change Horn Assembly
leading edge of the rotor blade to provide
protection against erosion. Inboard abrasion The pitch change horn is a machined alumi
strips are titanium. Outboard abrasion strips num bracket attached to the hub end of the
are nickel. Behind the lower edge of each pitchcase trailing edge. Pitch change links
abrasion strip is a fiberglass pad that resists low transfer control input to the rotor blades
angle of incidence abrasion. through the pitchcases.
Page 1
62-00-00 Revision 3
4. Main Rotor Hub Assembly the upper hub half and the non-rotating
components of the main rotor installation.
The main rotor hub assembly mounts the main
rotor system to the static support mast and is F. Hub Liner
driven by the main rotor drive shaft.
The hub liner is a stainless steel tube in the
The main rotor hub assembly consists of: center of the upper hub half that fits snugly
over the stationary support mast. During main
A. Upper and Lower Hub Halves rotor hub installation a hub retaining nut is
threaded to the top of the stationary support
The rotor hub halves are machined, hardened mast. The retaining nut presses the upper
aluminum alloy. Rotor hub halves mount and bearing inner race against the bearing
transmit drive force to the rest of the main rotor pre-load shim, which presses the hub liner
system rotating components. Moisture contami against a machined shoulder on the stationary
nation and corrosion are prevented by neo mast. The lower bearing inner race is an
prene and stainless steel spring seals. interference fit on the hub liner. The hub liner
B. Flexbeam also provides the inner contact surface for the
lower and center upper hub seals.
The flexbeam is attached between the rotor
blade and the main rotor hub. Flexing of the G. Drive Ring
beam allows rotor blades to move about the
The drive ring is a machined, hardened, and
feathering, flapping, and lead/lag axes without
anodized aluminum alloy two piece component.
the need for hinges. Flexbeams transfer driving
The drive ring is attached to the upper hub half
force from the hub to the rotor blades. The
by clamp up and to the lower hub half through
flexbeams are a composite structure made of
the striker plate brackets. The drive ring
laminated fiberglass. Flexbeam attachment
provides drive through the scissors to the
points are hardened stainless steel bushings
rotating swashplate.
embedded in the laminate. An elastomeric
flexbeam bumper is bonded around the H. Grounding Brushes and Straps
flexbeam to reduce flexbeam deflections during
rotor starts and stops. The grounding brushes and straps are the
grounding path from the pitchcases to the
C. Hub Plate stationary support mast. The brushes are
A hardened steel hub plate is sandwiched located on the drive ring at the upper scissors
between the hub halves to absorb centrifugal attachment point. The carbon brushes ground
loads. The hub plate also separates the the rotating hub assembly to the stationary
lead/lag legs of the flexbeams into the upper support mast through a groove at the bottom of
and lower hub halves. the hub liner. The straps (bonding jumpers)
provide positive bonding between the rotor
D. Fretting Buffer blade, pitchcases, and hub assembly.
The fretting buffer has been removed from the I. Droop Stop
helicopter. It is not necessary and made it
more difficult to get a good seal around the The droop stop limits the rotor blade droop
drive plate to main rotor hub joint. angle at low rotor speed. As the rotor blades
loose lift with reduced rotor speed, the droop
E. Tapered Roller Bearing Set stop roller contacts the striker plate on the main
rotor hub. The droop stop roller is mounted to
The tapered roller bearing sets transfer flight the pitchcase by the axle and lower damper cap.
and static loads between the rotating and The striker plate is fixed to the rotor hub drive
non-rotating sections of the main rotor hub. The ring by the droop stop striker support. The
upper bearing carries most of the load, and the droop stop striker plate and roller are made of
lower bearing acts as a follower, centering the stainless steel. The inner diameter of the droop
hub on the static mast of the helicopter. The stop roller is coated with molybdenum disulfide
tapered roller bearing sets are located between and needs no lubrication.
Page 2
5. Data Plates data. The data plates provide part number and
serial number identification for the main rotor
Data plates shall be bonded to the top of the hub assembly as a complete unit and the
rotor hub assembly in plain sight. Areas that upper hub assembly specifically. Exceptions
require specific processes, such as eddy current are the upper and lower bearings which have
inspections and web surfaces, should be avoided electrolytic etch marking.
(Ref. Main Rotor Upper Hub Inspection).
A. Data Plate Marking C. Overhaul Data Plates
Impression stamping directly on The overhaul data plate shall be fabricated

CAUTION the surface of an installed data and installed by the facility performing the
plate, or on the item itself, is prohibited. overhaul. The overhaul data plate shall be
marked to identify the most recent overhaul
Data provided on data plates may be applied by date and hub configuration.
engraving, electric vibrator, impression stamp
ing, or typewriter. If sufficient space is not Overhaul data plate marking shall provide the
available on existing plate to add information, operator with the following information:
the plate shall be replaced and all pertinent
data transferred to a new plate. Data shall not (1). Name of facility performing overhaul
be stamped directly on any part, assembly, or
item of equipment. (2). Part number
B. Identification Data Plates
(3). Time since new (TSN)
The rotor hub data (identification) plate
provides the operator with manufacturer's (4). Date of overhaul.
Page 3
62-00-00 Revision 3
ROTOR BLADE
ROTOR BLADE
RETENTION BOLTS
FLEXBEAM
BUMPER
PITCHCASE
UPPER
DRIVE DAMPER CAP DAMPER
GROUNDING
PLATE
STRAPS
FLEXBEAM
UPPER
CENTERING
HUB
BEARING
PITCH INBOARD
CHANGE ABRASION STRIP
HORN
LOWER
HUB
DRIVE
RING OUTBOARD
ABRASION STRIP
SCISSORS
TRIM TAB
ASSEMBLY
9G62-001A
Figure 1. Main Rotor System
Page 4
Revision 3 62-00-00
6. Upper Flight Controls Subsystem longitudinal and lateral flight control. The
stationary swashplate also transmits the
(Ref. Figure 2) control inputs to the rotating swashplate
The upper flight controls subsystem uniformly through the swashplate bearing.
transmits cyclic and collective inputs to the
C. Rotating Swashplate
main rotor blades. The outcome is lift about
the vertical, lateral and longitudinal control The rotating swashplate is located directly
axes of the helicopter. above and assembled to the stationary
The upper flight control subsystem consists of: swashplate by the swashplate bearing. The
rotating swashplate transfers control inputs to
A. Mixer Assembly the pitch links. The rotating swashplate is a
five star figure and is made of forged 7050
The mixer assembly transmits main rotor aluminum alloy.
hydraulic actuator inputs to the stationary
swashplate. The mixer assembly is mounted to D. Scissors Assembly
and pivots on two rod end bearings attached to
the static mast base. The scissors assembly transfers rotational
drive from the main rotor hub to the rotating
The mixer assembly utilizes three horizontal swashplate. The scissors assembly also
beams which are constructed of forged 7050 maintains the alignment of the rotating
aluminum alloy. The mixer also includes; an swashplate and main rotor positioning the
adjustable collective link, a non-adjustable arms of the swashplate directly below the
collective link, a longitudinal link, and a pitch change horns. The scissors are made of
lateral/anti-rotation link. anodized, machined, cast aluminum.
B. Stationary Swashplate
E. Pitch Links
The stationary swashplate is located directly
above the mixer and below the rotating The pitch links link the pitchcases to the
swashplate. The stationary swashplate is rotating swashplate and are constructed of
constructed of forged 7050 aluminum alloy. titanium. The pitch links twist the flexbeams
through the pitchcases which changes the
The stationary swashplate receives collective rotor blade angle in reference to the rotating
and cyclic control inputs and coordinates swashplate.
Page 5
62-00-00 Revision 3
SCISSORS DRIVE
LINK ASSEMBLY
PITCH LINK
ASSEMBLY
ROTATING SWASHPLATE AS STATIONARY SWASHPLATE

SEMBLY ASSEMBLY
LATERAL AND ANTI-ROTATION

LINK ASSEMBLY
NON-ADJUSTABLE COLLECTIVE
LINK ASSEMBLY
LONGITUDINAL MIXER ARM
COLLECTIVE MIXER ARM
LATERAL MIXER ARM
LONGITUDINAL
LINK ASSEMBLY
ADJUSTABLE COLLECTIVE
LINK ASSEMBLY
MIXER PIVOT NON-ADJUSTABLE COLLECTIVE

SUPPORT ASSEMBLY LINK ASSEMBLY
HYDRAULIC ACTUATOR
MOUNTING BRACKET
SUPPORT ROD ATTACHMENT
9G62016A
Figure 2. Upper Flight Controls Subsystem
Page 6
Revision 3 62-00-00
MAIN ROTOR SYSTEM

FAULT ISOLATION
1. Main Rotor System Troubleshooting The troubleshooting procedures in Table 101
are a brief summary of main rotor system
Rotor Vibrations faults which can occur. These procedures must
WARNING be used with serviceability checks and other
detailed procedures in this and other chapters
of the manual.
NOTE: First indications of trouble are usually
felt through cyclic or collective controls. Additional vibration and noise analysis
Make sure all controls are in good condition. investigation instructions are in Chapter 18.
Table 101. Main Rotor System Troubleshooting
Unusual or excessive Main rotor components Install main rotor components 620000
vibration. reinstalled in other than in original position, or do the 180000
original position. track and balance of main rotor.
Main rotor blades damaged. Inspect main rotor blades. 621000
Main rotor blades out of Track main rotor blades. 180000
track.
Vertical or lateral vibration. Main rotor components Install main rotor components 620000
reinstalled in other than in original position, or do the 180000
original position. track and balance of main rotor.
Main rotor hub or hub Inspect main rotor hub 622000
components damaged. assembly.
Main rotor blades out of Track main rotor blades. 180000

track.
Main rotor out of balance. Balance main rotor. 180000

Oneper revolution lateral Defective main rotor hub Replace defective main rotor 622000
beat in hover and cruise. Can damper. hub dampers.
also occur on ground during
warmup or shutdown.
Main rotor out of balance. Balance main rotor. 180000

Fiveper revolution or Worn pitch link bearings. Replace pitch link bearings. 623000
mediumfrequency beat.
Crossover rotor instability Cyclic control not centered Do the flexbeam inspection. 622000
High vertical, roll or pitch at low rotor speed.
vibration felt by the pilot Flexbeam damaged. Do the flexbeam inspection. 622000
which occurs between 35%
to 40% Nr on startup and
shutdown.
Overspeed. System inspection. 055000
Page 101
Page 102
Section
621000
Main Rotor Blade
MAIN ROTOR BLADE

1. Main Rotor Blade (1). Identify the locations of each main rotor
blade (2) and each blade retention bolt
A. Main Rotor Blade Removal (5 or 11). (Ref. Figure 402.)
Consumable Materials NOTE: During installation, the main rotor

(Ref. CSPSPM) blades and blade retention bolts are
Item Nomenclature installed in their original locations.
(2). Release the collective friction to remove
the preload of the flexbeams (ref.
Special Tools 67-10-00, Rotor Flight Controls
(Ref. CSPSPM) Removal / Installation).
Item Nomenclature
T2002 Ground Power Unit (a). Apply electrical power with ground
power unit (T2002) (ref.
CSP-900RMM-3, Electrical Power
Support the main rotor Maintenance Practices, Helicopter
WARNING blade during removal. Have Electrical Power).
one person on a maintenance stand.
(b). Push the collective friction release
Use care when removing the switch forward to release the
CAUTION main rotor blade. collective friction.
Damage can easily occur to thin plies in
the forward area of the root fitting (ref. (c). Raise the pilot collective stick
Figure 401). sufficiently to unload the collective
controls (approximately 15 to 30
Do not move the rotor blade tip up more
percent indication on the IIDS).
than 4.0 ft. (1.22 m) when the rotor is not
in operation. And do not move the
flexbeam up more than 1.0 in. (2.54 cm) (d). Remove electrical power (ref.
at the blade attach point. Damage to the CSP-900RMM-3, Electrical Power
flexbeam can occur. Maintenance Practices, Helicopter
Electrical Power).
Limit the pitchcase movement with pad
ding (cloth, foam, packing material, etc.) (3). Hold main rotor blade (2) up to release
with the blade removed. This prevents the stresses on the blade retention bolts
damage to the flexbeam and pitchcase. installed with the pitchcase (9).
(4). Remove lockwire and sealant from bolts

(4).
(5). Remove bolts (4) and disconnect bonding

jumpers (3) from main rotor blade (2).
(6). Early Configuration - Remove blade

retention bolts (5).
AREA OF THIN NOTE: Make small movements with the main

PLIES rotor blade as you remove the blade
9G62042
retention bolts. Make sure the bolts freely
Figure 401. Fragile Area of Rotor Blade come out of the blades.
Page 401
4
6 (NOTE)
7 7
5 5
2
8 14
8
3 13
EARLY CONFIGURATION 10
9
11
11
15
12
1
NOTE : BLADE RETENTION BOLT REQUIRES

SPECIAL TORQUE PROCEDURE. ENSURE MAINTEN
ANCE STEPS ARE FOLLOWED.
9G62002C
1. PITCH LINK 9. PITCHCASE
2. MAIN ROTOR BLADE 10. FLEXBEAM
3. BONDING JUMPER 11. BLADE RETENTION BOLT
4. BOLT 12. RETAINER, BOLT
5. BLADE RETENTION BOLT 13. SPRING CLIP
6. PLUNGER 14. CAM HANDLE
7. HEX NUT 15. ORING
8. LOCK PAWL 16. NUT
Figure 402. Removal and Installation of the Main Rotor Blade
Lubricant, Spray (C120) (a). Push in and hold plunger (6) with a
5/16-inch hex wrench. If necessary,
lightly tighten hex nut (7) to release
tension on internal locking
mechanism.
NOTE: (b). Loosen hex nut (7) until
Apply spray lubricant (C120) to exposed approximately two threads show.
blade retention bolt threads before you
loosen blade retention hex nut (7). (c). Push in lock pawl (8) on the bottom
of bolt (5).
Lightly tap the top of blade retention
bolts (5) with a mallet to loosen the bolts. (d). Release plunger (6).
You can lightly tighten hex nut (7) to (e). Remove blade retention bolt (5).
release some tension on the internal
locking mechanism. This lets the plunger (7). Current Configuration - Remove
move easily in the bolt. blade retention bolts (11).
Page 402
NOTE: Make small movements with the main Support the main rotor
rotor blade as you remove the blade reten WARNING blade during installation.
tion bolts. Make sure the bolts freely come Have one person on a maintenance
out of the blades. stand.
Do not use or spring clip (13) as
CAUTION a lever to remove blade reten Use care when installing the
tion bolts. This is an incorrect use of the CAUTION main rotor blade.
spring clip. The spring clip can loose shape
and tension if bent too much. Move the tab
Damage can easily occur to the thin plies
of the spring clip until there is sufficient
space to disengage from the nut. Use a sock in the forward area of the root fitting (ref.
et to hold and loosen nut (16), as necessary. Figure 401).
(a). Disengage spring clip (13). Do not move the rotor blade tip up more
than 4.0 ft. (1.22 m) when the rotor is not
Leave cam handles (14) and in operation. And do not move the
CAUTION spring clips (13) on removed flexbeam up more than 1.0 in. (2.54 cm)
blade retention bolts (11) in the OPEN posi at the blade attach point. Damage to the
tion. Bushings can become damaged when flexbeam can occur..
the bolt is not installed and cam handle is
closed.
Limit the pitchcase movement with pad
(b). Open cam handles (14). ding (cloth, foam, packing material, etc.)
around the flexbeam with the main rotor
Do not tap the bottom of the blade removed. This prevents damage to
CAUTION blade retention bolts. This will the flexbeam and pitchcase.
expand the bushings of the bolt and lock the
bolt in the blade.
NOTE: Install the main rotor blades and blade
(c). Lightly tap the top of blade retention
retention bolts at their original locations.
bolts (11) with a mallet to loosen the
bushings.
(d). Remove blade retention bolts (11) NOTE: Make sure the trim tab pitch is set at
and O-rings (15). zero degrees (ref. 18-00-00) if you install a
new blade or do not reinstall a blade in its
(8). Carefully remove main rotor blade (2) original location.
from pitchcase (9).
B. Main Rotor Blade Installation
(1). Align pitchcase (9) for the blade
(Ref. Figure 402) installation with the maintenance
stand.
(Ref. CSPSPM)
Item Nomenclature (2). Remove padding from pitchcase (9).
C702 Lockwire (3). Position the blade in pitchcase (9) with
flexbeam (10) between the top and
Special Tools bottom blade root bushings.
(Ref. CSPSPM)
Item Nomenclature
NA Push/Pull Spring Scale (50 to 150 lbf / (4). Align the holes in the blade root of
22.68 to 68.04 kgf) main rotor blade (2), pitchcase (9), and
flexbeam (10).
Page 403
4
3
0.005 INCH.
(0.127 MM)
9 (5 PL)
0.005 INCH.
(0.127 MM) 1 (10 PL)
6
SECTION A-A (TYPICAL)
7 (5 PL)
9G62096
1. BLADE RETENTION BOLT 6. PAWL

2. PLUNGER 7. PITCHCASE
3. THRUST WASHER 8. FLEXBEAM
4. HEX NUT 9. MAIN ROTOR BLADE
5. LOCK RING
Figure 403. Installation of (101) Blade Retention Bolts
Page 404
(Ref. Figure 403) (d). Install bolt (1) until thrust washer (3)
Blade Retention Bolts. is 0.010 to 0.040 inch (0.25 to 1.02
WARNING The expansion bushings of mm) from the top surface of
the blade retention bolts can lose pitchcase (7).
tension after installation. This can
(e). Make sure lock ring (5) is fully
cause a loss of the initial torque. Do the
outside of the bottom surface of
Special Inspection retorque
pitchcase (7).
procedures until there is no loss of
torque (ref. Section 05-20-10, Table 203, (f). With a 5/16-inch hex wrench, push
and Section 62-10-00, Inspection/ in and hold plunger (2) at top of the
Check, Torque Check of the (-101) bolt until hex nut (4) moves freely.
Blade Retention Bolts). Failure to do
this can cause the loss of a main rotor (g). Torque hex nut (4) to 800 in-lb
blade from the helicopter during (90.39 Nm).
operation.
(h). Remove the hex wrench.
Do not apply lubricant or
WARNING preservative on the blade
(i). Increase torque until plunger (2)
retention bolts. moves up.
Do not install -103 or -105 bolts
CAUTION with -101 bolts. 1). Do not torque more than 1100
in-lb (124.28 Nm).
(5). BLADE RETENTION BOLT (PN
900R3100001-101) - Install blade 2). If plunger (2) does not move up
retention bolt (1). before 1100 in-lb (124.28 Nm) of
torque, loosen hex nut (4) and
(a). Push in and hold plunger (2) with a repeat the torque sequence.
5/16-inch hex wrench.
(j). Make sure lock ring (5) expands
(b). Tighten hex nut (4) to remove all outside of the bottom surface of
play in the expandable bushings. pitchcase (7) after plunger (2) is in the
(c). Remove the hex wrench. UP position.
Do not align the slots of the (k). Check for a minimum gap of 0.005
CAUTION expandable bushings of blade inch (0.13 mm) between thrust
retention bolt (1). Make sure the slots are washer (3) and the top surface of
random and that adjacent slots are not pitchcase (7).
aligned.
(l). Check for a minimum gap of 0.005
NOTE: Make small movements with the main inch (0.13 mm) between lock ring
rotor blade as you install the blade (5) and the bottom surface of
retention bolts. Make sure the bolts freely pitchcase (7).
go into the blades. The bolts can be installed
by hand with minimum force. (m). Make sure pawl (6) is extended.
Page 405
2
8 3
10
FORCE F
6
4
BOTTOM SURFACE
5 1 (10 PL)
7 (10 PL)
SLOT
A
8 (5 PL) 11 (5 PL)
9 (5 PL)
9G62097
1. BLADE RETENTION BOLT 7. ORING

2. THRUST WASHER 8. RETAINER
3. CAM HANDLE 9. PITCHCASE
4. SPRING CLIP 10. FLEXBEAM
5. ADJUSTMENT NUT 11. MAIN ROTOR BLADE
6. LOCK RING
Figure 404. Installation of (103) Blade Retention Bolts
Page 406
(Ref. Figure 404) Do not align the slots of the

CAUTION expandable bushings of blade
Blade Retention Bolts. retention bolt (1). Make sure the slots are
WARNING The expansion bushings of
random and that adjacent slots are not
the blade retention bolts can lose aligned.
tension after installation. This can
cause a loss of the initial force. Do the NOTE: Make small movements with the main
Special Inspection retorque rotor blade as you install the blade
procedures (ref. Section 05-20-10, retention bolts. Make sure the bolts freely
Table 203, and Section 62-10-00, go into the blades. The bolts can be installed
Inspection/Check, Force Check of the by hand with minimum force.
(-103) Blade Retention Bolts). Failure
to do this can cause the loss of a main (d). Install blade retention bolt (1) in
rotor blade from the helicopter during retainer (8), pitchcase (9), flexbeam
operation. (10), and main rotor blade (11).
1). Make sure cam handle (3) is
Do not apply lubricant or aligned in the center of the slot of
WARNING preservative on blade retainer (8)
retention bolts.
2). Make sure lock ring (6) is fully
Use care when handling the outside the bottom surface of
CAUTION main rotor blade. pitchcase (9).
Do not move the rotor blade tip up more (e). The force required to turn cam
than 4.0 ft. (1.22 m) when the rotor is not handle (3), before the bushings
in operation. And do not move the expand, cannot be more than 5 lb
flexbeam up more than 1.0 in. (2.54 cm) (2.27 kg).
at the blade attach point. Damage to the
1). If the required force is more than
flexbeam can occur..
the specified limit, replace blade
Limit the pitchcase movement with retention bolt (1).
padding (cloth, foam, packing material,
Keep the bolt holes of retainer
etc.) around the flexbeam with the main CAUTION (8), pitchcase (9), flexbeam (10),
rotor blade removed. This prevents
damage to the flexbeam and pitchcase. and main rotor blade (11) in alignment as
you apply force. A misalignment during
Do not install -101 bolts with installation can damage a blade retention
CAUTION -103 or -105 bolts. If -103 and bolt.
-105 bolts are installed on the same rotor NOTE: Force F is when spring clip (4) has
head, equally space the bolts around the pushed across the bolt end, just before full
rotor head to prevent a rotor imbalance. engagement with adjustment nut (5).
(6). BLADE RETENTION BOLT (PN (f). Adjust the expandable diameter of
900R3100001-103) - Install blade blade retention bolt (1) with adjust
retention bolt (1). ment nut (5) until the Force F
necessary to close cam handle (3) is
(a). Install O-ring (7) under thrust 65 to 115 lb (29.48 to 52.16 kg) as
washer (2). you keep the bolt holes aligned.
(g). If necessary, turn adjustment nut (5),
(b). Put retainer (8) on top of pitchcase in the tightening direction only, to
(9). align the nut with the hex hole of
spring clip (4), without a recheck of
(c). Align the holes for the blade reten Force F.
tion bolts of retainer (8), pitchcase
(9), flexbeam (10), and main rotor (h). Move and center spring clip (4) over
blade (11). adjustment nut (5).
Page 407
NOTE: Listen for a click or snap when the (j). Make sure lock ring (6) is expanded
spring clip moves over the adjustment nut. outside the bottom surface of
pitchcase (9).
(k). Make sure the hex hole of spring clip
(i). Make sure cam handle (3) is centered (4) engages and is centered over
in the slot of retainer (8). adjustment nut (5).
2
3
4
9 8
11
1 (10 PL)
6 5 8 (10 PL)
BOTTOM SURFACE
SLOT
A A
9 (5 PL)
12 (5 PL)
10 (5 PL)
9g62-098
1. BLADE RETENTION BOLT 7. LOCK RING

2. TORQUE NUT 8. ORING
3. CAM HANDLE 9. RETAINER
4. THRUST WASHER 10. PITCHCASE
5. SPRING CLIP 11. FLEXBEAM
Figure 405. Installation of (105) Blade Retention Bolt
Page 408
(l). Make sure the gap between thrust Do not install -101 bolts with
washer (2) and retainer (8) is not CAUTION -103 or -105 bolts. If -103 and
more than 0.100 inch (2.54 mm). -105 bolts are installed on the same rotor
head, equally space the bolts around the
rotor head to prevent a rotor imbalance.
(m). Record the final installation force of
each blade retention bolt (1) in (7). BLADE RETENTION BOLT (PN
Rotorcraft Log Book for future special 900R3100001-105) - Install blade
inspections (ref. Section 05-20-10, retention bolt (1).
Table 203, Special Inspection - After
Component Installation, Main Rotor: (a). Install O-ring (8) under thrust
Blade Retention Bolt Torque Check) washer (4).
and force checks (ref. Section
62-10-00, Inspection/Check, Force (b). Put retainer (9) on top of pitchcase
Check of the (-103) Blade Retention (10).
Bolts).
(c). Align the holes for the blade
retention bolts of retainer (9),
(Ref. Figure 405) pitchcase (10), flexbeam (11), and
main rotor blade (12).
Blade Retention Bolts.
WARNING The expansion bushings of
Do not align the slots of the
the blade retention bolts can lose CAUTION expandable bushings of blade
tension after installation. This can retention bolt (1). Make sure the slots are
cause a loss of the initial torque. Do the random and that adjacent slots are not
Special Inspection retorque aligned.
procedures (ref. Section 05-20-10,
Table 203, and Section 62-10-00, NOTE: Make small movements with the main
Inspection/Check, Torque Check of the rotor blade as you install the blade retention
(-105) Blade Retention Bolts). Failure bolts. Make sure the bolts freely go into the
to do this can cause the loss of a main blades. The bolts can be installed by hand
rotor blade from the helicopter during with minimum force.
operation.
(d). Install blade retention bolt (1) in
Do not apply lubricant or retainer (9), pitchcase (10), flexbeam
WARNING preservative on blade (11), and main rotor blade (12).
retention bolts.
1). Make sure spring clip (5) is aligned
in the center of the slot of retainer
Use care when handling the (9).
CAUTION main rotor blade.
2). Make sure lock ring (7) is fully
Do not move the rotor blade tip up more outside the bottom surface of
than 4.0 ft. (1.22 m) when the rotor is not pitchcase (10).
in operation. And do not move the
flexbeam up more than 1.0 in. (2.54 cm) (e). Turn torque nut (2) with a torque
at the blade attach point. Damage to the wrench to make sure that the torque
flexbeam can occur.. necessary to turn cam handle (3)
before the bushings expand is not
Limit the pitchcase movement with more than 21 in-lb (2.37 Nm).
padding (cloth, foam, packing material,
etc.) around the flexbeam with the main 1). If the required torque is more than
rotor blade removed. This prevents the specified limit, replace blade
damage to the flexbeam and pitchcase. retention bolt (1).
Page 409
Keep the bolt holes of retainer (m). Record the final installation torque of
CAUTION (9), pitchcase (10), flexbeam each blade retention bolt (1) in the
(11), and main rotor blade (12) in alignment Rotorcraft Log Book for future special
as you torque the nut. A misalignment inspections (ref. Section 05-20-10,
during installation can damage a blade Table 203, Special Inspection - After
retention bolt. Component Installation, Main Rotor:
Blade Retention Bolt Torque Check)
and torque checks (ref. Section
NOTE: Torque is when spring clip (5) has 62-10-00, Inspection/Check, Torque
pushed across the bolt end, just before full Check of the (-105) Blade Retention
engagement with adjustment nut (6). Bolts).
(Ref. Figure 402)
(f). Torque torque nut (2) 350 to 450
Make sure the electrical bond
in-lb (39.54 to 50.84 Nm) as you CAUTION between the main rotor blades
keep the bolt holes aligned until cam
handle (3) closes. and pitchcases is correctly done. Damage to
the metal components of the main rotor
mast can occur.
(g). If necessary, turn adjustment nut (6), (8). Prepare bonding jumpers (3) and main
in the tightening direction only, to rotor blade (2) for electrical bonding
align the nut with the hex hole of (ref. CSP-SPM, Section 20-50-00,
spring clip (5). Electrical Bonding).
(9). Attach bonding jumpers (3) to main
(h). Move and center spring clip (5) over rotor blade (2) with bolts (4).
adjustment nut (6).
(a). Torque bolts (4) 15 to 20 in-lb (1.69
to 2.26 Nm).
NOTE: Listen for a click or snap when the
spring clip moves over the adjustment nut. (10). Test bonding jumper (3) attachments of
main rotor blade (2) and pitchcase (9)
for electrical bond, Class H (ref.
(i). Make sure spring clip (5) is centered CSP-SPM, Section 20-50-00,
in the slot of retainer (9). Electrical Bonding).
(11). Safety bolts (4) with lockwire (C702).
(j). Make sure lock ring (7) expanded Sealant, Fuel Resistant (C216)
outside the bottom surface of
pitchcase (10).
(k). Make sure the hex hole of spring clip (12). Seal the heads of bolts (4) with sealant
(5) engages and is centered on (C216) (ref. CSP-SPM).
adjustment nut (6).
(13). Do a main rotor track and balance as
necessary (ref. Section 18-00-00,
(l). Make sure the gap between thrust Vibration And Noise Analysis,
washer (4) and retainer (9) is not Maintenance Practices, Main Rotor
more than 0.100 inch (2.54 mm). Track And Balance).
Page 410
MAIN ROTOR BLADE

INSPECTION / TEST
1. Main Rotor Blade (a). if there is erosion, do a blend repair
of those areas (ref. CSP-SPM,
(Ref. Figure 601) Section 20-40-00, Mechanical
A. Main Rotor Blade Inspection Defects).
(1). Examine blade (1) for scratches, nicks, NOTE: For areas that cannot be blended out,
gouges, depressions and cracks. tell the MDHI Field Service Department to
get more information.
(a). Repairable damage is limited to
outboard trailing corner, maximum (2). Examine abrasion strips (2, 3) for
after removal of damage 0.50 inch corrosion.
(12.7 mm) radius from outboard
trailing corner. (a). If there is corrosion, remove it (ref.
(2). Do the inspection of main rotor blade Corrosion Removal).
(1) abrasion strip (ref. Procedure 1.B.).
(3). Do the inspection of main rotor blade (3). Inspect abrasion strips (2, 3) for pits.
(1) trim tab (ref. Procedure 1.C.).
(a). If the depth of a pit is more than
(4). Examine the root fairing for cracks, 0.030 inch (0.76 mm), tell the
depressions, or holes. MDHI Field Service Department.
(a). The maximum allowable repairable (b). If the depth is less than the specified
damage: limit, do a blend repair of the pits
Cracks cannot be more than 6.0 inch (ref. CSP-SPM, Section 20-40-00,
Mechanical Defects).
(15.24 cm) in length.
Depressions or holes with combined (4). Examine main rotor blade (1) for voids
areas no more than 0.30 inch2 (1.94 open to edge between inboard (2) and
cm2) (ref. Root Fairing Repair, Main outboard (3) abrasion strips.
Rotor Blade).
(a). If there is a void, tell the MDHI Field
(5). Examine blade (1) for loose retention Service Department for more infor
bolts (ref. Procedure 2.A., Procedure mation.
2.B., or Procedure 2.C., as applicable).
(5). Examine outboard abrasion strip (3)
B. Main Rotor Blade Abrasion Strip adjacent to weight pocket for cracks.
Inspection
(a). No cracks are permitted.
(Ref. CSPSPM) (b). If there are cracks, tell the MDHI
Item Nomenclature Field Service Department to get more
information.
(6). Examine area where outboard abrasion
Do not do a fluorescent pene strip (3) is overlapped by the edge of
CAUTION trant inspection (FPI). Once the inboard abrasion (2) strip for cracks.
surface of the blade is contaminated, that
area cannot be bonded. (a). Repair cracks that are within the
limits (ref. Repair, Outboard Abra
(1). Examine abrasion strips (2, 3) for sion Strip Crack Repair, Main Rotor
erosion. Blade).
Page 601
Sta. 203
BOTTOM SURFACE OF BLADE

Sta. 41 Sta. 70 Sta. 171
WEIGHT POCKET
AREAS WHERE CRACK IN THE
OUTBOARD ABRASION STRIP FILLER MATERIAL MIGHT OCCUR.
INSPECT THIS EDGE

FOR CRACKS
TE TE
BLADE
TAB
SEGMENT
9G62085
Figure 601. Main Rotor Blade Inspection (Sheet 1 of 2)

(b). If the cracks do not meet these abrasion (2) strip for voids open to edge.
specified limits, tell the MDHI Field Sealant, Fuel Resistant (C216)
Service Department:
1). No more than one span-wise crack

is permitted. (a). If there are voids, seal the voids in
this area with sealant (C216) (ref.
2). A crack that is more than 1.75 Environmental Sealing Methods).
inch (44.5 mm) from the overlap
NOTE: A tap test can be done to find a disbond.
edge of the inboard abrasion strip A scan must be used to confirm the size of
(2) is not permitted. the disbond.
(8). Do a tap test over top and bottom of
3). A crack that does not follow the abrasion strips (2, 3) (ref. CSP-SPM,
leading edge or goes in a chord- Section 20-90-00, Coin Tap Inspec
wise direction is not permitted. tion).
NOTE: Tell the MDHI Field Service Depart
ment if anomalies (disbonds, FOD, and
(7). Examine outboard abrasion strip (3) voids) are more than the specified limits
where it overlaps the edge of inboard that follow.
Page 602
4 INBOARD TIP 2 3 OUTBOARD TIP

NOTE 4 NOTE 4
6
0.5 INCH (12.7 MM) TYP

AFTER DAMAGE REMOVAL
1 6
5
2
0.50 INCH
(12.7 MM)
NOTE 1
NOTE 2
0.15 INCH (3.8 MM)

NOTE 3
0.15 INCH (3.8 MM)

NOTE 3
0.50 INCH (12.7 MM) 0.50 INCH (12.7 MM)
LE LE
1.00 INCH (25.4 MM)

NOTE 4
1.00 INCH
INBD OUTBD
(25.4 MM)
NOTE 4
TE TE
0.15 INCH (3.8 MM) 0.15 INCH (3.8 MM)

NOTE 3 NOTE 3
NOTE 1: EXAMINE ZONE FOR VOIDS ON LEADING EDGE ALONG ENTIRE LENGTH OF BOTH STRIPS.
NOTE 2: EXAMINE ZONE FOR VOIDS.
NOTE 3: NO ANOMALIES WITHIN THIS AREA FOR LENGTH OF BOTH STRIPS.
NOTE 4: NO ANOMALIES WITHIN 1.00 INCH (25.4 MM) OF INBOARD AND OUTBOARD EDGES.
9G62015F
1. MAIN ROTOR BLADE 4. MAIN ROTOR BLADE ROOT FAIRING

2. INBOARD ABRASION STRIP 5. MAIN ROTOR BLADE TRIM TAB
3. OUTBOARD ABRASION STRIP 6. MAIN ROTOR BLADE OUTBOARD TRAILING CORNER
Figure 601. Main Rotor Blade Inspection (Sheet 2 of 2)
Page 603
(a). Anomalies greater than 0.25 inch Do not do a fluorescent pene

(6.4 mm) in diameter and within 1.0 CAUTION trant inspection (FPI). Once the
inch (2.54 cm) of each other must be surface of the blade is contaminated, that
considered a single anomaly. area cannot be bonded.
(b). Anomalies must be less than or equal (1). Examine the trim tabs (5) for cracks.
to 2.0 inch2 (12.9 cm2) with a (a). If there are cracks, tell the MDHI
maximum chordwise width of 0.50 Field Service Department to get more
inch (12.7 mm). information and instruction.
(c). Accumulated anomalies from Sta. 70 NOTE:
to Sta. 123 must be less than or Some indications can appear on the sur
equal to 8.0 inch2 (51.6 cm2) of total face parallel to the chord-wise direction.
area. These are usually the bondlines between
adjacent segments of the tab, not cracks.
(d). Accumulated anomalies from Sta.
123 to Sta. 171 and Sta. 171 to Sta. Cracks in the filler material or paint
188 must be less than or equal to 5.0 around trim tab (5) do not represent
inch 2 (32.26 cm2) of total area. structural damage and are permitted.
(2). Do a coin tap inspection for anomalies
(e). Accumulated anomalies from Sta. of trim tab (5) to blade skin bond (ref.
188 to Sta. 203 must be less than or CSP-SPM, Section 20-90-00, Coin Tap
equal to 1.75 inch2 (11.29 cm2) of Inspection).
total area.
(f). Acceptable anomalies no closer than ment if anomalies are more than the speci
1.00 inch (25.4 mm) to the spanwise fied limits that follow.
ends and no closer than 0.15 inch
(3.8 mm) to aft edges of abrasion (a). Anomalies less than or equal to 0.30
strips (2, 3). inch (7.6 mm) aft to trailing edge of
blade are acceptable for length of
trim tab (5).
(9). Inspect inboard tip of inboard abrasion
strip (2) for disbond. If disbond is (b). Anomalies less than or equal to 0.50
discovered, do these steps: inch (12.7 mm) chordwise is per
mitted.
(a). Examine blade (1) after every flight.
(c). Accumulated anomalies less than or
(b). Record length of disbond, number of equal to 0.25 inch2 (1.61 cm2) of
flights, and flight hours from discov total area per segment are permitted.
ery until disbond limit is reached. (3). Do a coin tap inspection for anomalies
over trim tab (5) aft of the blade
(c). Once disbond limit is reached, trailing edge (ref. CSP-SPM, Section
contact field service representative 20-90-00, Coin Tap Inspection).
for further instruction.
C. Main Rotor Blade Trim Tab Inspection ment if anomalies are more than the speci
fied limits that follow.
Consumable Materials (a). Anomalies separated by less than

(Ref. CSPSPM) 0.50 inch (12.7 mm) must be
Item Nomenclature considered a single anomaly.
C216 Sealant, Fuel Resistant (b). An anomaly less than or equal to
0.25 inch2 (1.61 cm2) is permitted.
Page 604
(c). Accumulated anomalies less than or

equal to 0.50 inch2 (3.24 cm2) of the
total area are permitted.
(4). Examine trim tab (5) for voids open to
the edge.
(a). If there is a void in this area, seal

voids with sealant (C216) (ref.
Environmental Sealing Methods).
Page 605
1 (NOTE)
4
3
0.005 INCH
(0.127 MM)
8
0.005 INCH.
(0.127 MM)
6
NOTE: THERE IS A SPECIAL TORQUE PROCEDURE FOR BLADE RETENTION BOLT.
MAKE SURE YOU FOLLOW THE PROCEDURE.
9G62093
1. BLADE RETENTION BOLT

2. PLUNGER 6. PAWL
4. HEX NUT 8. FLEX BEAM
5. LOCK RING 9. MAIN ROTOR BLADE
Figure 602. Torque Check for the (101) Blade Retention Bolts
Page 606
Do not apply lubricant or (d). Remove electrical power (ref.

WARNING preservative on blade CSP-900RMM-3, Electrical Power
retention bolts. Maintenance Practices, Helicopter
Electrical Power).
CAUTION (2). Support main rotor blade (9) in line
with the angle of pitchcase (7).
DO NOT stand on helicopter cowlings or
hand holds to do these checks. (3). Push in plunger (2) at top of blade
Do not move the rotor blade tip up more retention bolt (1) with a 5/16-inch hex
than 4.0 ft. (1.22 m) when the rotor is not wrench.
in operation. And do not move the (4). Make sure the torque on hex nut (4) is
flexbeam up more than 1.0 in. (2.54 cm) 800 in-lb (90.39 Nm) minimum.
at the blade attach point. Damage to the
flexbeam can occur. (a). If hex nut (4) moves before you get
this torque, continue to torque to 800
2. Blade Retention Bolts in-lb (90.39 Nm).
(b). If the torque is more than 800 in-lb
Special Tools (90.39 Nm) no more torque checks
(Ref. CSPSPM) are required until the bolt is
Item Nomenclature removed.
T2002 Ground Power Unit (5). Remove hex wrench and make sure
NA Push/Pull Spring Scale (50 to 150 lbf / plunger (2) returns to the full up
22.68 to 68.04 kgf) position.
(a). If plunger (2) does not return,
A. Torque Check of the Blade Retention increase torque on hex nut (4) until
Bolts (PN 900R3100001101) the plunger moves to the full up
position or until the torque is 1100
(Ref. Figure 602) in-lb (124.28 Nm).
NOTE: NOTE: If plunger (2) does not move up before
Make sure the lock ring (5) is fully outside 1100 in-lb (124.28 Nm), depress the
the bottom surface of pitchcase (7). plunger, loosen blade retention bolt (1), and
do the torque sequence again.
Do not loosen blade retention bolts (1).
(6). After plunger (2) is in the up position,
(1). Release the collective friction to remove make sure lock ring (5) has expanded
the preload of flexbeams (ref. outside the bottom surface of pitchcase
67-10-00, Rotor Flight Controls (7).
Removal / Installation).
(7). Make sure there is a 0.005 inch (0.13
(a). Apply electrical power with ground mm) minimum gap between thrust
power unit (T2002) (ref. washer (3) and the upper surface of
CSP-900RMM-3, Electrical Power pitchcase (7).
Maintenance Practices, Helicopter
Electrical Power). (8). Make sure there is a 0.005 inch (0.13
mm) minimum gap between lock ring
(b). Push the collective friction release (5) and the bottom surface of pitchcase
switch forward to release the (7).
collective friction.
(9). Make sure pawl (6) is extended.
(c). Raise the pilot collective stick (10). Record the locations of blade retention
sufficiently to unload the collective bolts (1) that lost torque in the logbook.
controls (approximately 15 to 30
percent indication on the IIDS). (a). Deleted.
Page 607
(11). Repeat this procedure for each of the

remaining 9 blade retention bolts (1).
1 (NOTE)
11
7
GAP 2
8
10

FORCE F

6
5
4
NOTE: THERE IS A SPECIAL TORQUE PROCEDURE FOR BLADE RETENTION BOLT.
MAKE SURE YOU FOLLOW THE PROCEDURE. BOTTOM SURFACE
9G62
1. BLADE RETENTION BOLT 7. ORING

2. THRUST WASHER 8. RETAINER
3. CAM HANDLE 9. PITCHCASE
4. SPRING CLIP 10. FLEX BEAM
5. HEX NUT 11. MAIN ROTOR BLADE
6. LOCK RING
Page 608
B. Force Check of the Blade Retention Bolts NOTE: If necessary, make small movements of
(PN 900R3100001103) the main rotor blade to help loosen the
bushings.
(Ref. Figure 603)
(5). Do a check of Force F with a push/pull
NOTE: Blade retention bolt (1) can be adjusted spring scale.
by turning hex nut (5) located at the end of
bolt. NOTE: Force F is when spring clip (4) has
pushed across the bolt end, just before hex
(1). Release the collective friction to remove nut (5) is engaged.
the preload of the flexbeams (ref. (a). Force F must be 65 to 115 lbf (29.48
Section 67-10-00, Rotor Flight to 52.16 kgf).
Controls Removal/Installation).
1). The force cannot be less than 90
(a). Apply electrical power with ground percent of the recorded final
power unit (T2002) (ref. installation force or 65 lbf (29.48
CSP-900RMM-3, Electrical Power kgf) which ever is greater. (ref.
Maintenance Practices, Helicopter Section 62-10-00, Main Rotor
Electrical Power). Blade Removal/Installation).
(b). Push the collective friction release (b). If Force F is equal to or more than 90
switch forward to release the percent of the recorded final
collective friction. installation force and greater than 65
lbf (29.48 kgf) go to Step (6).
(c). Raise the pilot collective stick
sufficiently to unload the collective (c). If Force F is less than 90 percent of
controls (approximately 15 to 30 the recorded final installation force or
percent indication on the IIDS). less than 65 lbf (29.48 kgf) which
ever is greater retorque blade
(d). Remove electrical power (ref. retention bolt (ref. Section 62-10-00,
CSP-900RMM-3, Electrical Power Main Rotor Blade Removal/-
Maintenance Practices, Helicopter Installation).
Electrical Power).
(d). If necessary, turn hex nut (5), in the
(2). Support main rotor blade (11) in line tightening direction only, to align and
with the angle of pitchcase (9). center the hex nut (5) with the
hex-shaped hole of spring clip (4)
Do not use the spring clip as a without a recheck of Force F.
CAUTION lever to remove blade retention (6). Move and center spring clip (4) over hex
bolts. The spring clip can loose shape and nut (5).
tension if bent too much. This is an incorrect
use of the spring clip. Move the tab of the NOTE: Listen for a click or snap when the
spring clip until there is sufficient space to spring clip moves over the hex nut.
disengage from the hex nut. Use a socket to
hold and loosen hex nut, as necessary. (7). Make sure lock ring (6) is expanded
outside the bottom surface of pitchcase
(3). Disengage spring clip (4) from hex nut (9).
(5). (8). Make sure the hex-shaped hole of
Do not tap the bottom of the spring clip (4) is centered over hex nut
CAUTION blade retention bolts. This will (5).
expand the bushings of the bolt and lock the (9). Make sure cam handle (3) is centered in
bolt in position. the slot of retainer (8).
(4). Lightly tap the top of blade retention (10). Make sure the gap between thrust
bolt (1) with a mallet to loosen the washer (2) and retainer (8) is not more
bushings. than 0.100 inch (2.54 mm).
Page 609
(11). Record the locations of blade retention (12). Repeat this procedure for the remaining
bolts (1) that lost force in the Rotorcraft 9 blade retention bolts (1).
Log Book.
1 (NOTE)
12
2 3
4
10 9 8
11
7
NOTE: THERE IS A SPECIAL TORQUE PROCEDURE FOR BLADE RETENTION BOLT. 6
MAKE SURE YOU FOLLOW THE PROCEDURE. 5
BOTTOM SURFACE
9G62095
1. BLADE RETENTION BOLT 7. LOCK RING

2. TORQUE NUT 8. ORING
3. CAM HANDLE 9. RETAINER
5. SPRING CLIP 11. FLEX BEAM
Page 610
C. Torque Check of the Blade Retention NOTE: If necessary, make small movements of
Bolts (PN 900R3100001105) the main rotor blade to help loosen the
bushings.
(Ref. Figure 604)
(5). Do a torque check on torque nut (2).
NOTE: Blade retention bolt (1) can be adjusted
by turning adjustment nut (6) located at the (a). The torque must be 350 to 450 in-lb
end of bolt. (39.54 to 50.84 Nm).
1). The loss of torque cannot be more
(1). Release the collective friction to remove than 10 percent of the recorded
the preload of the flexbeams (ref. final installation torque (ref.
67-10-00, Rotor Flight Controls 62-10-00, Main Rotor Blade
Removal/Installation). Removal/Installation).
(a). Apply electrical power with ground 2). The torque cannot be less than 350
power unit (T2002) (ref. in-lb (39.54 Nm).
CSP-900RMM-3, Electrical Power
Maintenance Practices, Helicopter (b). If the torque is equal to or more than
Electrical Power). 90 percent of the recorded final
installation torque and greater than
(b). Push the collective friction release 350 in-lb (39.54 Nm) go to Step (6).
switch forward to release the
collective friction. (c). If the torque is less than 90 percent
of the recorded final installation
(c). Raise the pilot collective stick torque or less than 350 in-lb (39.54
sufficiently to unload the collective Nm) retorque blade retention bolt
controls (approximately 15 to 30 (ref. 62-10-00, Main Rotor Blade
percent indication on the IIDS). Removal/Installation).
(d). Remove electrical power (ref. (d). If necessary, turn adjustment nut (6),
CSP-900RMM-3, Electrical Power in the tightening direction only, to
Maintenance Practices, Helicopter align the nut with the hex-shaped
Electrical Power). hole of spring clip (5) without a
recheck of the torque.
(2). Support main rotor blade (12) in line
(6). Move and center spring clip (5) over
with the angle of pitchcase (10).
adjustment nut (6).
Do not use the spring clip as a NOTE: Listen for a click or snap when the
CAUTION lever to remove blade retention spring clip moves over the adjustment nut.
bolts. The spring clip can loose shape and
tension if bent too much. This is an incorrect (7). Make sure lock ring (7) expanded
use of the spring clip. Move the tab of the outside the bottom surface of pitchcase
spring clip until there is sufficient space to (10).
disengage from the hex nut. Use a socket to
hold and loosen hex nut, as necessary. (8). Make sure the hex-shaped hole in
spring clip (5) is centered over
(3). Disengage spring clip (4) from adjustment nut (6).
adjustment nut (6). (9). Make sure spring clip (5) is centered in
Do not tap the bottom of the the slot of retainer (9).
CAUTION blade retention bolts. This will (10). Make sure the gap between thrust
expand the bushings of the bolt and lock the washer (4) and retainer (9) is 0.100
bolt in position. inch (2.54 mm).
(4). Lightly tap the top of blade retention (11). Record the locations of blade retention
bolt (1) with a mallet to loosen the bolts (1) that lost torque in the Rotor
bushings. craft Log Book.
Page 611
(12). Repeat this procedure for the remaining 1). Visually examine the assembled
9 blade retention bolts (1). bolt for damage.
D. Gap Check of the Blade Retention Bolts 2). Re-install an undamaged bolt (ref.
NOTE: Do this check for the -103 and -105 Section 62-10-00, Main Rotor
blade retention bolts only. Blade Removal/Installation).
(Ref. Figure 603 and Figure 604) (2). Measure the gap at two locations, 180
degrees apart, with a feeler gage.
(1). Visually examine blade retention bolts
for a gap between washer and retainer.
(a). The gap is more than 0.100 inch
(a). Make sure O-rings are installed. (2.54 mm) remove blade retention
bolt (ref. Section 62-10-00, Main
1). Install missing O-rings (ref. Rotor Blade Removal/Installation).
Section 62-10-00, Main Rotor
Blade Removal/Installation). 1). Visually examine the assembled
(b). If there is a gap, go to Step (2). bolt for damage.
(c). If there is no gap, remove blade 2). Re-install an undamaged blade

retention bolt (ref. Section 62-10-00, retention bolt (ref. Section
Main Rotor Blade Removal/Installa 62-10-00, Main Rotor Blade
tion). Removal/Installation).
Page 612
MAIN ROTOR BLADE

REPAIRS
1. Root Fairing Repair, Main Rotor Blade (b). Air dry for a minimum of 15 min
utes at ambient temperature.
Use this repair procedure for cracks no longer
than 6.00 inch (15.24 cm), and depressions or NOTE: If filler is not applied within 2 hours,
holes with total areas no more than 0.3 inch2 do the solvent wipe cleaning (Step (2).)
(194 mm2). again.
A. Main Rotor Blade Root Fairing Filling of Adhesive, Epoxy (C438)
Depression or Hole
(Ref. Figure 801)
Consumable Materials Do not machine mix epoxy as it

(Ref. CSPSPM) CAUTION will cause air to be included in
Item Nomenclature the epoxy which will reduce its strength.
C438 Adhesive, Epoxy (3). Thoroughly mix epoxy adhesive (C438)
by weight in accordance with manufac
C814 Abrasive Paper turers instructions.
Protective Equipment (4). Apply epoxy adhesive (C438) to crack,

depression or hole to build up the
damaged area to the approximate
surface contour.
NOTE: Application of filler to a hole cannot be

Do not damage laminate fibers more than 30 grams.
CAUTION immediately adjacent to the
damaged area. (5). Cure epoxy adhesive (C438) for:
(1). Remove top coat and primer from the 24 hours at ambient temperature, or
blade root end fairing surface (ref.
2 hours at 150 to 1705F (65.6 to
CSP-SPM, 20-40-00, Paint Removal
76.75C), or
Mechanical).
1 hour at 170 to 1905F (76.7 to
(a). Remove top coat and primer adjacent 87.85C).
to the damaged area by an additional
1.00 inch (25.4 mm). Protective Equipment
(b). Vacuum to remove sanding residue.

Do not damage laminate fibers
CAUTION immediately adjacent to the
damaged area.
(2). Solvent wipe fairing surface with a (6). Fair filler material to adjacent surface
clean cloth dampened with solvent contour by sanding with wet or dry
cleaner (C429), or equivalent. abrasive paper (C814) or finer.
(a). Wipe with a clean dry cloth. (a). Vacuum to remove sanding residue.
Page 801
B. Main Rotor Blade Root Fairing Doubler (5). Brush a thin coat of epoxy resin, the size
Installation of the doubler ply, onto the nonporous
release film on the opposite side from the
(Ref. Figure 801) dimensional mark of the plies.
Consumable Materials (6). Place the doubler plies onto the epoxy
(Ref. CSPSPM) resin, apply another thin coat of resin,
Item Nomenclature and cover with additional pieces of
C429 Solvent Cleaner nonporous release film.
C814 Abrasive Paper
C501 Fiber Cloth, EGlass (7). Using a plastic squeegee, carefully
C504 Resin, Epoxy work the resin into the fabric. Work
excess resin outboard of the fabric.
(8). Cut the doubler plies and nonporous
release film to the finished dimension
marked on the nonporous release film.
(1). Wipe fairing surface with solvent NOTE: Fiberglass orientation is optional.
cleaner (C429) or equivalent, and air
dry for a minimum of 15 minutes.
(9). Place the first (smaller) ply onto the
NOTE: The first doubler ply overlaps the faired repair, ensuring not to entrap air.
filler by 0.5 - 0.75 inches (12.7 - 19.05 mm).
The second doubler ply overlaps the first ply (10). Place the second ply onto the first ply.
by 0.5 - 0.75 inches (12.7 - 19.05 mm)
(2). Mark pieces of nonporous release film, (11). Cover repair with nonporous release film
approximately 3.00 inches (7.62 cm.) and work out any trapped air or
larger than the doubler ply with the wrinkles.
finished dimension of the doubler ply.
Resin, Epoxy (C504) NOTE: If using elevated temperature cure, cure
temperature must be monitored with cali
brated equipment.
(12). Cure 24 hours at room temperature or 12

Do not machine mix epoxy as it hours at room temperature followed by 2
CAUTION will cause air to be included in hours "0.5 hours at 180 F "10
the epoxy which will reduce its strength. (82 C "6).
(3). Thoroughly mix epoxy resin (C504) by Protective Equipment

weight in accordance with manufactur
er's instructions.
Fiber Cloth, E-Glass (C501)
(13). Fair by sanding with wet or dry

abrasive paper (C814) or finer.
(4). Cut two plies of fiber cloth (C501)to
fabricate the required doublers with an (14). Touch up Main Rotor Blade Paint (Ref.
additional 1.0 inch (2.54 cm.) outside CSP-SPM).
dimension on each doubler.
Page 802
BLADE ROOT FAIRING
9G62049A
Figure 801. Blade Root Fairing Repair

2. Blade Trailing Edge Repair Solvent Cleaner (C429)
(Ref. Figure 802)
This repair is applicable to the blade trailing

edge from the trailing edge notch to the (3). Wipe fairing surface with solvent
trailing edge tip. cleaner (C429) or equivalent, and air
dry for a minimum of 15 minutes.
(4). Mark pieces of nonporous release film,
Consumable Materials approximately 3.00 inches (7.62 cm.)
(Ref. CSPSPM) larger than the doubler ply with the
Item Nomenclature finished dimension of the doubler ply.
C410 Adhesive, Epoxy Paste Do not machine mix epoxy as it
C501 Fiber Cloth, EGlass CAUTION will cause air to be included in
C807 Sandpaper the epoxy which will reduce its strength.
C429 Solvent Cleaner Adhesive, Epoxy Paste (C410)
Main rotor blade trailing edge

CAUTION must be straight at completion
(5). Thoroughly mix epoxy paste adhesive
(C410) by weight in accordance with
of repair.
Protective Equipment Fiber Cloth, E-Glass (C501)
(6). Cut two plies of fiber cloth (C501)to

(1). Remove damaged fibers, maximum fabricate the required doublers with an
after removal 0.50 in (12.7 mm) additional 1.0 inch (2.54 cm.) outside
radius from trailing edge. dimension on each doubler.
Do not sand into or damage fi (7). Brush a thin coat of epoxy resin, the size
CAUTION berglass fibers. of the doubler ply, onto the nonporous
release film on the opposite side from the
dimensional mark of the plies.
(2). Sand top and bottom of blade to remove
topcoat and primer using sandpaper (8). Place the doubler ply onto the epoxy
(C807) . resin, apply another thin coat of resin,
Page 803
and cover with additional piece of NOTE: If using elevated temperature cure, cure
nonporous release film. temperature must be monitored with cali
brated equipment.
(9). Using a plastic squeegee, carefully
work the resin into the fabric. Work (15). Cure repair 24 hours @ Room Temperature
excess resin outboard of the fabric. or 90 Minutes @160F "10 (71 " 6C).
Protective Equipment
(10). Cut the doubler plies and nonporous
release film to the finished dimension
marked on the nonporous release film.
NOTE: Fiberglass orientation is optional.

(16). Using epoxy adhesive (C438), fill and
(11). Place the first (smaller) ply onto the fair with sandpaper (C807) or finer.
repair, ensuring not to entrap air.
(17). Inspect trailing for straightness.
(12). Place the second ply onto the first ply. Trailing edge must be straight.
(13). Cover repair with nonporous release film (18). Touch up Main Rotor Blade Paint (Ref.
and work out any trapped air or CSP-SPM).
wrinkles.
(19). Perform blade balance at an approved
(14). Vacuum bag top and bottom repair area MDHI approved facility. Contact your
together and apply vacuum pressure, MDHI Field Service Representative for
20-29 Inches of mercury. more information.
VACUUM PORT
VACUUM SOURCE VACUUM BAG FILM

BREATHER

RELEASE FILM

REPAIR

PART

9G62-087
SHEET 1 NOTES:
1. VACUUM BAG FILM 3. BREATHER AIRTECH N10

AIRTECH #7400, #KM1300, OR WN1500
2. VACUUM BAG SEALANT
AIRTECH GS2133, OR GS43MR
Figure 802. Blade Tip Repair (Sheet 1 of 2)
Page 804
NOTE: TRAILING EDGE REPAIR ALLOWED AT ANY POINT IN

AREA
BETWEEN TIP OF BLADE AND NOTCH 8.04 IN (20.42
cm) 0.75 IN R 1.20 IN
FROM TIP. 0.93 IN R (19.05 mm) (3.05 cm)
MINIMUM 1.0 IN (2.54 cm) BETWEEN REPAIRS. (23.62 mm)
COVER PLY
NOTCH 2ND PLY 2.20 IN

NOTE 1ST PLY (5.59 cm)
BLADE 1.70 IN
TRAILING (4.32 cm)
EDGE
8.04 IN (20.42 cm)
0.5 IN
BOTTOM VIEW (12.7 mm) 1.40 IN
TYP 1.90 IN (3.56 cm)
(4.83 cm)
2.40 IN 2.40 IN
(6.10 cm) (6.10 cm) DAMAGE
1.90 IN BOTTOM VIEW BLADE TIP AREA
(4.83 cm) NOTCH OPPOSITE
1.40 IN
3.56 cm)
BLADE 4.80 IN
TRAILING 1.70 IN (12.19 cm)
EDGE 1ST PLY (4.32 cm)
2.20 IN 3.80 IN
0.75 IN R 2ND PLY (5.59 cm) (9.65 cm)
(19.05 mm) 0.93 IN R 1.20 IN
(23.62 mm) COVER PLY
0.93 IN R COVER PLY (3.05 cm)
(23.62 mm) 2.80 IN
(7.1 cm)
1.20 IN
(3.05 cm) 2ND PLY 2.20 IN
1.12 IN R (5.59 cm)
(2.84 cm) TOP VIEW 1ST PLY
1.70 IN
BLADE TIP (4.32 cm)
NOTCH OPPOSITE
BLADE 1.0 IN
0.75 IN R (2.54 cm)
TRAILING 3.80 IN (19.05 mm) 0.5 IN MAXIMUM
EDGE (9.65 cm) DAMAGE BLADE
(12.7 mm)
2.80 IN MAXIMUM AREA TRAILING
1.40 IN
(7.1 cm) 3.56 cm) EDGE
BOTTOM VIEW
TRAILING EDGE
DAMAGE
AREA 1.70 IN
0.75 IN R 1ST PLY (4.32 cm)
(19.05 mm) 2.20 IN
2ND PLY (5.59 cm)
0.93 IN R
(23.62 mm) COVER PLY
4.80 IN 1.20 IN
1.12 IN R (12.19 cm) (3.05 cm)
(2.84 cm)
TOP VIEW TRAILING
EDGE
9G62051C
Figure 802. Blade Tip Repair (Sheet 2 of 2)
Page 805
3. Abrasion Strip Edge Sealing, Main Rotor strip edges with sealing compound
Blade (C212), sealing compound (C213), or
(Ref. Figure 803). sealing compound (C234).
(a). Use a plastic spatula or flat edged
Consumable Materials tool to smooth sealing compound
(Ref. CSPSPM) down into groove behind abrasion
Item Nomenclature strip.
C213 Sealing Compound, Corrosion Inhibitive (3). Remove masking tape.
C234 Sealing Compound Do not heat more than 170 5F
CAUTION (77 5C).
(1). Apply masking tape to blade on two
(4). Cure for a minimum of 8 hours at
sides of area to be sealed.
room temperature or at 150 5F (66 5C)
NOTE: You can be use sealing compound for 2 hours.
(C234) when sealing compound is applied in
colder temperatures.
(2). Seal all of top and bottom abrasion

AREA TO BE SEALED
(BOTTOM OF BLADE SHOWN)
INBOARD ABRASION STRIP OUTBOARD ABRASION STRIP
SEAL UPPER EDGE
SEAL LOWER EDGE 9G62060A
Figure 803. Abrasion Strip Edge Sealing
Page 806
4. Outboard Abrasion Strip Crack Repair, (3). Clean surface with solvent cleaner
Main Rotor Blade (C429) or equivalent, and wipe dry
immediately.
(Ref. Figure 804)
(4). Allow the surface to air dry for a
minimum of 15 minutes.
(Ref. CSPSPM) Bonding, General (C403)
Item Nomenclature
C403 Bonding, General
C717 Tape, Polyethylene Sealing Compound (C202)

The abrasion strip is 0.075
CAUTION inches (75 mil.) thick at the
leading edge. Use extreme care while work
ing with the abrasion strip to avoid damage
The abrasion strip must be re to the Main Rotor Blade.
CAUTION placed if:
More than one crack exists, (5). Apply sealing compound (C202) or
adhesive, general bonding (C403) , to
Crack is beyond 1.75 inches (4.445 cm.), the surface of the crack.
Crack does not follow the leading edge.
(6). Rub the sealant/adhesive into the crack
This repair may be repeated only once if the until the crack is filled.
crack is still within the 1.75 inches (4.445
cm.) of the inboard abrasion strip overlay. (7). Remove excess sealant/adhesive.
(1). Measure the visible crack length from (8). Allow the sealant to cure at room
the overlap edge of the inboard abra temperature for 24 hours.
sion strip to the end of the crack.
(9). Cover the repair area with polyethylene
(a). If the entire crack is within tape (C717). The covered area must be
1.75 inches (4.445 cm.), the crack a minimum of 2 inches (5.08 cm.) in
may be repaired. the span direction beyond the repair.
(2). Lightly abrade the surface of the (10). Monitor the crack after each flight for
cracked area with scouring pad (C817). more growth.
Page 807
(BOTTOM OF BLADE SHOWN)
OUTBOARD
ABRASION
INBOARD STRIP
ABRASION ABRASION STRIP
STRIP OVERLAY 1.75 IN (4.445 CM)
REPAIRABLE
AREA

TAPE OVERLAP
9G62077
Figure 804. Outboard Abrasion Strip Crack Repair Area
Page 808
Section
622000
Main Rotor Hub
Assembly
MAIN ROTOR HUB ASSEMBLY

1. Main Rotor Hub Assembly (7). Remove bolts (4) in order of 12 thru 1,
as shown on safety ring (5). Remove
(Ref. Figure 401) safety ring.
(8). Install two bolts (4) in retention nut (3).
Consumable Materials Do not fully tighten bolts.
(Ref. CSPSPM)
Item Nomenclature Retention nut (3) has Left hand
CAUTION ed threads.
C702 Lockwire (9). Turn retention nut (3) clockwise, use
two bolts (4). Remove retention nut.
Special Tools
(Ref. CSPSPM) (10). Remove nut retainer (7).
Item Nomenclature (11). Install helicopter sling (T901), on rotor
T901 Helicopter Sling hub.
(a). Put clevis fittings (9) of helicopter
A. Main Rotor Hub Assembly Removal sling (11) to align with rotor hub web
(12).
CAUTION up more than 4.0 ft. (1.22 m) (b). Install clevis bolts or pins (10) through
when the rotor is not in operation. And do clevis fittings and rotor hub web.
(2.54 cm) at the blade attach point. Dam (12). Attach helicopter sling to hoist.
age to the flexbeam can occur. (13). Remove rotor hub (1).
(1). Remove main rotor blades (Ref. Section B. Main Rotor Hub Assembly Installation
62-10-00).
Post warning notice in cock
WARNING pit and on GSE panel stating
that flight controls are disconnected.
(2). Disconnect pitch links from main rotor

hub pitch case assemblies (Ref. Section CAUTION up more than 4.0 ft. (1.22 m)
62-30-00).
(3). Disconnect scissors drive link from not move the flexbeam up more than 1.0 in.
main rotor hub drive ring assembly (2.54 cm) at the blade attach point. Dam
(Ref. Section 62-30-00). age to the flexbeam can occur.
(1). Install helicopter sling (T901) on main
(4). Remove main rotor drive plate (Ref.
rotor hub.
Section 63-10-00).
(a). Put clevis fittings of helicopter sling to
NOTE: Fretting buffer may stick to underside align with rotor hub web.
of drive plate.
(b). Thread clevis bolts or pins through
(5). If necessary, remove fretting buffer (2). clevis fittings and rotor hub web.
(6). Remove lockwire from bolts (4). (2). Attach helicopter sling to hoist.
Page 401
Make sure main rotor hub (14). Install bolts in retention nut. Torque
WARNING seats fully on static mast. bolts in sequence 1 through 12. Refer to
numbers on safety ring. Torque to 45-55
in-lbs (5.0-6.2 Nm).
CAUTION
(15). Torque in sequence again to95-105
Make sure hub upper seal and seal spring in-lbs (10.7-11.8 Nm).
are not damaged by upper bearing cone
during hub assembly installation. (16). Loosen bolts in reverse order of torque
If hub assembly does not seat correctly on sequence and remove.
mast, do not force into position. Remove
hub assembly, determine cause, correct the (17). Remove safety ring.
problem, and reinstall. (18). Install two bolts into retention nut. Do
not fully tighten bolts
(3). Make sure static mast is clean. Install
main rotor hub on static mast. (19). Hand tighten retention nut until nut is
against nut retainer.
(4). Inspect hub upper seal and seal spring
(Ref. Main Rotor Hub Upper Bearing (20). Remove bolts from retention nut.
Inspection).
NOTE:
(5). Remove helicopter sling. If necessary, loosen retention nut to align
bolt holes with holes in safety ring.
(6). Install nut retainer open side up.
Retention nut must be on static mast far
Retention nut has Left handed enough for safety ring to engage static
CAUTION threads. mast tabs of ring with notches in top of
static mast and not slip off mast when
NOTE: Make sure threads of retention nut and bolts are fully torqued.
bolts have no oil or grease contamination. Bolts must not clamp safety ring to reten
tion nut after last torque sequence.
(7). Install main rotor hub retention nut
counterclockwise on static mast. (21). Install safety ring, align tabs of ring
with notches in top of static mast.
(8). Apply antiseize compound (C220) to
threads of two bolts. (22). Apply anti-seize compound (C220) to
bolts.
(9). Install two bolts into retention nut. Do
not fully tighten bolts NOTE: Do not loosen bolts between each torque
sequence.
(10). Hand tighten retention nut until nut is
(23). Install bolts and torque in sequence 1
against nut retainer. thru 12 to 35-45 in-lbs (3.9-5.0 Nm)..
Refer to sequence numbers on safety
(11). Remove bolts from retention nut. ring.
NOTE: If necessary, loosen retention nut to (24). Torque in sequence again to80-90
align bolt holes with holes in safety ring. in-lbs (9.0-10.1 Nm) three times.
Turn the main rotor hub 360 degrees
(12). Install safety ring over retention nut, before each torque sequence.
align tabs of ring with notches in top of
static mast. (25). Torque in sequence again and again
until torque becomes stable. Turn main
(13). Apply antiseize compound (C220) to rotor hub 360 degrees before each
threads of bolts. torque sequence.
Page 402
(27). Install main rotor hub drive plate (Ref.

WARNING Section 63-10-00).
Make sure lock tabs of safety ring are
engaged with slots in static mast. (28). Connect scissors drive link to main
Make sure safety ring is free to move. rotor hub drive ring assembly (Ref.
Section 62-30-00).
If safety ring is not free to move, re
move and install retention nut.
(29). Connect pitch links to main rotor hub
Make sure NO part of lockwire over
pitch case assemblies (Ref. Section
laps opening in center of mast.
62-30-00).
(26). Safety bolts together in sets of three.
Use lockwire (C702). (30). Install main rotor blades (Ref. Section
62-10-00).
NOTE: Do not install fretting buffer. Fretting
buffer is not necessary and its removal will
make it easier to apply the environmental (31). Do the main rotor track and balance
seal around main rotor hub and drive plate. (Ref. Section 18-00-00).
5
4 (12 PL)
11
3 (NOTE)
2 (DO NOT INSTALL) 6
12
10
NOTE: THERE IS A SPECIAL TORQUE SEQUENCE FOR THE RETENTION NUT.

MAKE SURE YOU FOLLOW ALL MAINTENANCE STEPS. 9G62063C
1. MAIN ROTOR HUB 7. NUT RETAINER

2. FRETTING BUFFER DO NOT INSTALL 8. UPPER SEAL
3. RETENTION NUT 9. CLEVIS FITTINGS
4. BOLT 10. CLEVIS BOLT OR PIN
5. SAFETY RING 11. HELICOPTER SLING
6. STATIC MAST 12. BUSHED HOLE IN ROTOR HUB WEB
Figure 401. Main Rotor Hub Assembly and Lifting Sling
Page 403
2. Main Rotor Hub Damper (8). Remove sealant from cap (6) and
pitchcase (2).
(Ref. Figure 402)
NOTE:
Consumable Materials Dampers must be installed or replaced as
(Ref. CSPSPM) a set. A set is one upper and one lower
Item Nomenclature damper of the same pitch case.
C702 Lockwire Before you remove dampers, identify each
C211 Sealing Compound, Corrosion Inhibitive damper location, position, and alignment
C229 Sealant, Conductive (e.g., blue blade, top, and an arrow that
C418 Release Agent
shows inboard direction).
Damper sets must be installed at same
location, position, and alignment as re
A. Main Rotor Hub Damper Removal moved.
(9). Remove nut (12) and washer (13) from
upper damper (10). Remove damper.
not move the flexbeam up more than 1.0 in. (10). Remove nut (12) and washer (13) from
(2.54 cm) at the blade attach point. Dam lower damper (14). Remove damper.
B. Main Rotor Hub Damper Installation
NOTE: This task is for the removal of one damp
er set at a time with the main rotor hub NOTE:
installed on the helicopter, and is typical.
This task is for the installation of one
(1). Lift main rotor blade approximately level damper set with the main rotor hub
and put a support below it. Or remove it installed on the helicopter, and is typical.
(Ref. Section 62-10-00). Removed dampers must be installed in
same location, position, and alignment as
(2). Release collective friction unit and move removed (e.g., blue blade, top, and an ar
collective up until outboard end of row that shows inboard direction).
pitchcase is approximately 90 to the
static mast (Ref. Section 67-10-00). Dampers must be replaced as a set.
Damper caps and shims must be installed
CAUTION at same location as removed.
Damper shims are free and not attached (1). If dampers are new, do the procedure
to damper or damper cap. that follows:
Upper and lower damper must have same (a). Temporarily install upper and lower
quantity of shims installed. damper cap on pitchcase using bolts
(3). Remove and discard lockwire from bolts and washers. Torque bolts.
(3). Remove bolts and washers (4).
(b). Measure and record dimension from
(4). Remove lower damper cap (1) and outside center of upper damper cap to
shim(s) (5). outside center of lower damper cap.
(5). Remove adhesive from bolts (7). (c). Remove damper caps from pitchcase.
(6). Remove and discard lockwire from bolts NOTE: Do not use nuts again if nut can be
(7). Remove bolts (7), washers (8), and installed by hand.
bonding jumpers (9).
(d). Install lower damper on centering
(7). Remove upper damper cap (6) and bearing with washer and nut. Torque
shim(s) (5). nut.
Page 404
(e). Install upper damper on centering NOTE: The same quantity of shims must be
bearing with washer and nut. Torque installed in upper and lower damper instal
nut. lations.
NOTE: Do not install damper shims at this time. Table 1. Main Rotor Damper Shim Quantity
(f). Install lower damper cap on pitchcase Dimension Qty.
with bolts and washers. Torque bolts. 0.1080.142 in. (2.7433.606 mm) None
Release Agent (C418) 0.0970.107 in. (2.4632.717 mm) 2 (1 ea.)
0.0850.096 in. (2.1592.438 mm) 4 (2 ea.)
0.0770.084 in. (1.9552.133 mm) 6 (3 ea.)
0.0690.076 in. (1.7521.930 mm) 8 (4 ea.)
(g). Apply release agent (C418) to upper
surface of pitchcase. (q). If necessary, remove damper caps
Sealant, Conductive (C229) and add shims.
(2). If dampers were removed, do the
procedure that follows:
NOTE: Do not use nuts again if nut can be
installed by hand.
(h). Apply sealant (C229) on two semicir
cular electrical bond areas on bottom (a). Install lower damper on centering
side of the upper damper cap. bearing with washer and nut. Torque
nut.
(i). Install upper damper cap, bolts (3),
and washers (4). (b). Install upper damper on centering
bearing with washer and nut. Torque
(j). At center bolt holes, prepare surface nut.
for electrical bond (Ref. CSP-SPM).
(c). Install lower damper cap on pitchcase
Loose bonding jumpers rub on with bolts and washers. Torque bolts.
CAUTION the pitch case and cause wear.
Make sure bonding jumpers are aligned in
an X and tie-wrapped in the center.
(k). Install bonding jumpers, bolts (7),

and washers (8).
(d). Apply release agent (C418) to upper
(l). Connect bonding jumpers together surface of pitchcase.
where they are across each other. Put
tie-wraps 2 in. apart. Sealant, Conductive (C229)
(m). Torque all upper damper cap bolts.

(n). Measure and record dimension from
outside center of upper damper cap to (e). Apply sealant (C229) on two semicir
outside center of lower damper cap. cular electrical bond areas on bottom
side of the upper damper cap.
(o). Subtract the dimension recorded in
Step (b). from the dimension obtained (f). Install upper damper cap with bolts
in Step (n). (3) and washers (4).
(p). Use the difference to find damper (g). At center bolt holes, prepare surface
shim quantity (Ref. Table 1). for electrical bond (Ref. CSP-SPM).
Page 405
Loose bonding jumpers rub on (2). Remove and discard cotter pin (17).
CAUTION the pitch case and cause wear. Remove nut (18), and washer (19).
Make sure bonding jumpers are aligned in Remove centering bearing (11).
an X and tie-wrapped in the center.
B. Centering Bearing Installation
(h). Install bonding jumpers, bolts (7),
and washers (8). NOTE: This task is typical for main rotor hub
centering bearing installation.
(i). Connect bonding jumpers together
where they are across each other. Put Lubricant, Solid Film (C101)
tie-wraps 2 in. apart.
(j). Torque all upper damper cap bolts.
(3). Safety bolts, use lockwire (C702).
(1). Spray threads of snubber bolt (20) with
Sealing Compound (C211) solid film lubricant (C101).
(2). Install centering bearing, nut, and
washer. Torque nut 300-360 in-lb
(33.90-40.67 Nwm) and install new
cotter pin.
(4). Environmentally seal bolts (3 and 7),
use sealing compound (C211) (Ref. (3). Install main rotor hub dampers.
CSP-SPM).
4. Main Rotor Pitchcase
CAUTION up more than 4.0 ft. (1.22 m) (Ref. Figure 402)
when the rotor is not in operation. And do A. Pitchcase Removal
(2.54 cm) at the blade attach point. Dam NOTE: If more than one pitchcase is removed,
age to the flexbeam can occur. identify all removed components to make
sure they are installed in their initial posi
(5). Lower or install main rotor blade (Ref. tion.
Section 62-10-00).
(6). Do the main rotor hub droop angle test. CAUTION up more than 4.0 ft. (1.22 m)
(7). Do the main rotor track and balance
3. Main Rotor Centering Bearing
(1). Remove main rotor blade (Ref. Section
(Ref. Figure 402) 62-10-00).
Consumable Materials (2). Remove main rotor hub dampers.

(Ref. CSPSPM) (3). Disconnect pitch link from pitch case
Item Nomenclature (Ref. Section 62-30-00).
C101 Lubricant, Solid Film
(4). Remove pitchcase (2) from main rotor
hub (15).
A. Centering Bearing Removal
B. Pitchcase Installation
NOTE: This task is typical for main rotor hub
centering bearing removal. NOTE: Make sure all components are installed
in their initial positions, for easy track and
(1). Remove main rotor hub dampers. balance.
Page 406
Do not move the rotor blade tip (2). Install main rotor hub dampers.
when the rotor is not in operation. And do (3). Connect pitch link to pitch case (Ref.
not move the flexbeam up more than 1.0 in. Section 62-30-00).
(4). Install main rotor blade (Ref. Section
(1). Install pitchcase on main rotor hub. 62-10-00).
7
2 PL
8
3 9 (2 PL)
4 PL
4
6 15
11
19
5
12
13
18
10
17
2
20
16
14
13
12
5
1
DRAIN HOLE 4 (6 PL)

3 (6 PL)
9G620064A
1. LOWER DAMPER CAP 11. CENTERING BEARING

2. PITCHCASE 12. NUT
3. BOLT 13. WASHER
4. WASHER 14. LOWER DAMPER
5. SHIM 15. MAIN ROTOR HUB
6. UPPER DAMPER CAP 16. FLEXBEAM
8. WASHER 18. NUT
9. BONDING JUMPER 19. WASHER
10. UPPER DAMPER 20. SNUBBER BOLT
Figure 402. Main Rotor Hub Damper, Feathering Bearing, and Pitchcase Installation
Page 407
5. Droop Stop Roller

6 6
5 1
(Ref. Figure 403)
5
Consumable Materials 8
(Ref. CSPSPM)
Item Nomenclature
C309 Primer 7
A. Droop Stop Roller Removal 4

4
NOTE: This task is typical for main rotor droop 3

stop roller removal. 3
(1). Remove lower damper cap assembly. 2

9G62011B
1. DAMPER CAP
2. COTTER PIN
(2). Remove and discard cotter pins (2). 3. NUT
4. WASHER
5. WASHER
(3). Remove nuts (3), washers (4), bolts (6), 6. BOLT
washer (5), and roller (7) with axle (8). 7. DROOP STOP ROLLER
8. DROOP STOP AXLE
(4). Remove droop stop axle from roller. Figure 403. Main Rotor Droop Stop Roller
B. Droop Stop Roller Installation 6. Main Rotor Droop Stop Striker Plate
(Ref. Figure 404)

NOTE: This task is typical for main rotor droop
stop roller installation.
(Ref. CSPSPM)
(1). Install droop stop axle in roller. Item Nomenclature
Primer (C309)
A. Striker Plate Removal

stop striker plate removal.
(2). Apply a coat of primer (C309) to shank Do not move the rotor blade tip
of bolts. CAUTION up more than 4.0 ft. (1.22 m)
(3). While primer is still wet, install roller not move the flexbeam up more than 1.0 in.
with bolts, washers, and nuts. Torque (2.54 cm) at the blade attach point. Dam
nuts 15-45 in-lbs (1.6-5.0 Nwm) and age to the flexbeam can occur.
install new cotter pins.
(1). Lift main rotor blade approximately level
and put a support below it. This will lift
(4). Install lower damper cap assembly. droop stop roller off striker plate.
Page 408
(2). Remove and discard cotter pins (1). bonding jumpers(16), and bolts (15).
Remove nuts (2), washers (3), bolts (4), Remove droop stop support (7).
striker plate (5) and shim (6).
NOTE: If you will install a new droop stop sup
B. Striker Plate Installation port, do the step that follows.
NOTE: This task is typical for main rotor droop (5). Remove and discard cotter pins (1).
stop striker plate installation. Remove nuts (2), washers (3), bolts (4),
striker plate (5), and shims (6).
B. Droop Stop Support Installation
stop support installation.
(1). Apply anti-seize compound (C220) to (1). If droop stop support is new, do the
bolts (4). steps that follow.
(2). Install bolts, striker plate, shim, (a). Install shims, striker plate, bolts,
washers, and nuts. Torque nuts and washers, and nuts. Torque nuts
install new cotter pins. 20-25 in-lbs (2.26-2.82 Nwm).
(3). Do the main rotor hub droop angle test. (b). Install new cotter pins.
7. Main Rotor Droop Stop Support (2). Prepare surface for electrical bond (Ref.
CSP-SPM).
(Ref. Figure 404)
(3). Install bolts, washers, bonding jump
ers, droop stop support, washers, and
Consumable Materials nuts. Torque nuts 36-46 in-lbs
(Ref. CSPSPM) (4.07-5.20 Nwm).
Item Nomenclature
C211 Sealing Compound, Corrosion Inhibitive (4). Install new cotter pins.
(5). Test for Class S electrical bond (Ref.
A. Droop Stop Support Removal CSP-SPM).
NOTE: This task is typical for main rotor droop If you install more than one
CAUTION droop stop support, you must
stop support removal.
torque nuts you removed to the procedure
Do not move the rotor blade tip shown in Flexbeam Installation. If you do
CAUTION up more than 4.0 ft. (1.22 m) not do the procedure, damage to main rotor
when the rotor is not in operation. And do hub can occur.
(6). Record locking (run-on) torque for nut
and add to torque value.
(7). Install bolt, washers, and nut. Torque
(1). Lift main rotor blade approximately level
nut 370-420 in-lbs (41.8-47.45 Nwm)
and put a support below it. This will lift
plus (+) locking torque.
droop stop roller off striker plate, or
remove blade. Sealing Compound (C211)
and bolt (11).
(3). Remove sealing compound from bolts
(15). (8). Cover bolt heads (15) with sealing
compound (C211) (Ref. CSP-SPM.
Remove nuts (13), washers (14), (9). Do the main rotor hub droop angle test.
Page 409
8. Main Rotor Grounding Brush (1). Install bolts, grounding assembly,

washers, and nuts. Torque nuts 20-25
(Ref. Figure 404) in-lbs (2.26-2.82 Nwm)
A. Grounding Brush Removal (2). Install new cotter pins.
NOTE: This task is typical for main rotor (3). Install main rotor grounding brush.
grounding brush removal.
(1). Disconnect scissors link from main 10. Drive Ring Assembly
rotor drive ring assembly (Ref. Section (Ref. Figure 404)
62-30-00).
A. Drive Ring Assembly Removal
(2). Remove setscrew (22).
(1). Remove droop stop supports.
(3). Remove grounding brush (23).
(2). Remove grounding brushes.
B. Grounding Brush Installation
(3). Remove nuts (24), washers (25),
NOTE: This task is typical for main rotor
countersunk washers (26), and bolts
grounding brush installation.
(27). Remove drive ring assemblies (28).
(1). Install grounding brush and setscrew.
B. Drive Ring Assembly Installation
(2). Tighten set screw until it stops, do not
Make sure mating surfaces be
tighten more than 45 in-lbs (5.08 Nm). CAUTION tween drive ring halves and
(3). Connect scissors link to main rotor drive ring to main rotor hub are clean and
drive ring assembly (Ref. Section have no unwanted material. Unwanted ma
62-30-00). terial between drive ring halves or drive
ring and main rotor hub can cause drive
9. Main Rotor Grounding Assembly ring to crack.
(Ref. Figure 404) (1). Install drive ring assemblies, bolts,
countersunk washers, washers, and
A. Grounding Assembly Removal
nuts. Do not tighten nuts.
NOTE: This task is typical for main rotor (2). Turn drive ring assembly so scissors
grounding assembly removal.
link can be connected.
(1). Remove main rotor grounding brush.
NOTE: After you torque nuts (24), make sure
(2). Remove and discard cotter pins (17). there is an approximately equal gap at drive
ring assembly mating ends.
(3). Remove nuts (18), washers (19), bolts
(20), and grounding assembly (21). (3). Torque nuts (24) 130-180 in-lbs
(14.69-20.34 Nwm).
B. Grounding Assembly Installation
(4). Install grounding brushes.
NOTE: This task is typical for main rotor
grounding assembly installation. (5). Install droop stop supports.
Page 410
11
10
18
17
24
19 23 15
2 PL 27 (2 PL)
21 14
22
16 (2 PL) 26 (2 PL)
1 (2 PL)
2 (2 PL)
3 (2 PL)
7
6
5
4 (2 PL)
28
28
9 25 (2 PL)
8
24 (2 PL)
14 (2 PL)
12 (2 PL) 13 (2 PL)
9G62065A
1. COTTER PIN 15. BOLT

2. NUT 16. BONDING JUMPER
4. BOLT 18. NUT
6. SHIM 20. BOLT
7. DROOP STOP SUPPORT 21. GROUNDING ASSEMBLY
8. NUT 22. SETSCREW
9. WASHER 23. GROUNDING BRUSH
10. WASHER 24. NUT
11. BOLT 25. WASHER
12. COTTER PIN 26. COUNTERSUNK WASHER
13. NUT 27. BOLT
14. WASHER 28. DRIVE RING ASSEMBLY
Figure 404. Main Rotor Hub Droop Stop and Grounding Brush Installation
11. Hub Plate, Main Rotor 12. Lower Hub, Main Rotor
(Ref. Flexbeam Removal and Installation) (Ref. Flexbeam Removal and Installation)
Page 411
4 6
14 (5 PL)
3 1.034-1.035 IN
5 (2.626-2.629 cm)
7
11
VIEW LOOKING UP 14 ADHESIVE

15
12
13
16
14
1
8 12
10
3
B 10
8
D
5 E
15 (5 PL) 2 1 9
6
11 A
C 15
7
4
9 2
13
TORQUE SEQUENCE
VIEW LOOKING DOWN
TOP VIEW
9G62020C
1. NUT 9. FLEXBEAM BOLT

2. WASHER 10. LOWER HUB
3. COUNTERSUNK WASHER 11. UPPER HUB
4. BOLT 12. HUB PLATE
5. COTTER PIN 13. FLEXBEAM
6. NUT 14. LEAD LEG SHIM (UPPER)
7. WASHER 15. LAG LEG SHIM (LOWER)
8. COUNTERSUNK WASHER 16. IDENTIFICATION PLATE
Figure 405. Main Rotor Hub Flexbeam Installation
Page 412
13. Flexbeam, Main Rotor Hub NOTE:

A. Flexbeam Removal Make sure lead/lag shims are correctly at
tached in hub half and in serviceable con
(Ref. Figure 405) dition. If unserviceable, Contact MDHI
Field Service Department for correction
(1). Remove main rotor hub. procedure.
(2). Remove all pitchcases. Aid of 1 or 2 persons is recommended.
(3). Remove drive ring assembly. (2). Put upper hub half top down on a work
bench.
(4). Remove nuts (1), washers (2), counter Move flexbeam legs as necessary while
sunk washers (3), and bolts (4). you install hub plate.
(5). Remove and discard cotter pins (5). (3). Install upper leg of flexbeams in
flexbeam pockets and install hub plate.
NOTE: Aid of 1 or 2 persons is recommended.
(4). Install lower hub half and install bolts,
CAUTION countersunk washers, washers, and
nuts. Do not tighten nuts at this time.
When you remove bolts (9) and separate
hub halves, flexbeams will not be kept in (5). Install flexbeam bolts, countersunk
hub. Flexbeams can fall and damage to washers, washers, and nuts. Do not
flexbeam can occur. tighten nuts at this time.
Do not use force to remove flexbeam bolt (6). Turn main rotor hub top up.
(9). Damage to lead/lag shims (14 and 15)
can occur. (7). Record locking (run-on) torque for each
nut and add to torque values.
(6). Remove nuts (6), washers (7), counter
(8). Do these steps for flexbeams installed
sunk washers (8), and flexbeam bolts
on 900R1101000-111 hub assemblies:
(9).
(a). Torque nuts (6) in sequence A, B, C,
(7). Separate lower hub half (10) from D, and E 800 in-lb (90.39 Nm).
upper hub half (11).
(b). Torque bolts (9) in sequence A, B, C,
(8). Remove hub plate (12) and flexbeams D, and E 1600 to 1650 in-lb (180.78
(13). to 186.42 Nm).
B. Flexbeam Installation Do not torque more than 1800
CAUTION in-lb (203.37 Nm) plus (+)
(Ref. Figure 405)
locking torque during alignment. Damage
to the hub assembly can occur.
(Ref. CSPSPM) (c). Align the pin holes in bolt (9) with
Item Nomenclature the castellations of nut (6).
C101 Lubricant, Solid Film (d). Install new cotter pins (5).
(e). Torque nuts (1) in sequence 1 thru 10
Lubricant, Solid Film (C101) 110 to 210 in-lb (12.43 to 23.73
Nm).
(f). Torque nuts (1) again in sequence 1
thru 10 320 to 420 in-lb (36.16 to
47.45 Nm).
(1). Apply solid film lubricant (C101) to
threads of bolts (4) and flexbeam bolts (g). Torque nuts (1) at locations 11, 12,
(9). Dry in air a minimum of 6 hours. 13, 14, and 15:
Page 413
1). Find the run-on torque for bolts 14. Lead/Lag Leg Wear Shim, Main Rotor Hub
(4).
(Ref. Figure 405)
2). Torque nuts (1) to the run-on
torque for bolts (4). Consumable Materials
(Ref. CSPSPM)
Item Nomenclature
a). Stop when the torque of nuts (1)
begins to be more than the C814 Abrasive Paper
run-on torque of bolt (4). C412 Adhesive Promoter, Epoxy
NOTE: Bolts (4) must be snug, but not tight. C426 Adhesive
C309 Primer
(9). Do these steps for flexbeams installed C418 Release Agent
on 900R1101000-113 thru -125 hub
assemblies: Special Tools
(Ref. CSPSPM)
(a). Torque nuts (6) in sequence A, B, C, Item Nomenclature
D, and E 800 to 850 in-lb (90.39 to T908 Flex Beam Wear Shim Installation Tool
96.04 Nm) plus (+) locking torque.
A. Lead/Lag Leg Wear Shim Removal

(b). Torque nuts (6) again in sequence
1600 to 1650 in-lb (180.78 to NOTE: Lead/Lag Leg shim removal is typical.
186.42 Nm) plus (+) locking torque.
Do not score or damage hub sur
CAUTION face material when you remove
Do not torque more than 1650
CAUTION in-lb (186.42 Nm) plus (+) shims.
locking torque during alignment. Damage
to the hub assembly can occur. (1). Remove lead/lag leg shims (14 or 15).
(2). Remove old adhesive and primer

(c). Align the pin holes in bolt (9) with material from main rotor hub (10 or 11)
the castellations of nut (6). shim mating surface.
(d). Install new cotter pins (5). B. Lead/Lag Leg Wear Shim Installation
NOTE: Lead/Lag Leg shim installation is typi

(e). Torque nuts (1) in sequence 1 thru 15 cal.
160 to 210 in-lb (18.08 to 23.73
Nm) plus (+) locking torque. (1). Make sure shim mating surface of main
rotor hub is sufficiently rough, use 400
grit abrasive paper (C814) or equiva
(f). Torque nuts (1) again in sequence 1 lent.
thru 15 370 to 420 in-lb (41.80 to
47.45 Nm) plus (+) locking torque. Alcohol, Isopropyl (C419)
(10). Put torque strips on nuts (1, 6) (ref.

CSP-SPM, 21-10-00).
(11). Install pitchcase assemblies (ref. (2). Wipe surface, use isopropyl alcohol
Procedure 4.B.). (C419). Dry 15 minutes in air.
Page 414
Adhesive Promoter, Epoxy (C412) (6). Install shim in hub and align hole in
shim with bolt hole in hub.
NOTE: Do not let edges of shim be on fillet radii

in pocket of hub.
(3). Apply a thin layer of adhesive promoter
(C412) to mating surfaces of hub and (7). Install flex beam wear shim installa
shims. Dry a minimum of 1 hour in air. tion tool (T908). Clamp with sufficient
force to make sure there is a good bond.
(8). Make sure depth dimension after clamp
installation is 1.034 to 1.035 inch
(26.26 to 26.29 mm).
(4). Apply release agent (C418) or equiva (9). Cure at ambient temperature a
lent to flex beam wear shim installation minimum of 24 hours or at 150 to
tool (T908). 1705F (65.5 to 76.65C) for 2 hours
minimum.
Adhesive (C426)
Primer (C309)
(5). In less than 2 hours after adhesive

promoter is dry, apply a thin layer
(approximate thickness 0.005 to 0.015 (10). After cure, remove unwanted adhesive
inch (0.13 to 0.38 mm)) of adhesive from edges of shim. Touch up with
(C426) to shim mating surface. primer (C309) (ref. CSP-SPM).
Page 415
15
6

1
2
4 GREASE

5
7

13
8
8 12
14
GREASE
10
5
GREASE
11
9
9G62047
1. UPPER BEARING 9. LOWER SEAL

2. BEARING CONE 10. LOWER BEARING
3. BEARING ROLLER 11. HUB LINER
4. BEARING CAGE 12. CENTER SEAL
5. BEARING CUP (OUTER RACE) 13. HUB SHIM
6. UPPER SEAL 14. UPPER HUB
7. SEAL SPRING 15. UPPER BEARING REMOVAL TOOL (T907)
8. SEAL STOP
Figure 406. Bearing and Seal Removal/Installation
Page 416
15. Upper Hub Assembly (4). Install nut retainer and hub retention
nut (ref. Main Rotor Hub Installation).
A. Upper Hub Buildup
17. Upper Bearing, Upper Hub Assembly
(Ref. Figure 406)
(Ref. Figure 406)
Upper hub assembly records, to include part
number, serial number, and necessary
dimensions, are to be kept with the hub. Consumable Materials
(Ref. CSPSPM)
Assembly records are to be put in the Rotor Item Nomenclature
craft Log Book at hub installation. C104 Grease
16. Upper Seal, Upper Hub Assembly Special Tools

(Ref. CSPSPM)
T907 Upper Bearing Removal Tool
(Ref. CSPSPM)
Item Nomenclature A. Upper Bearing Removal
C104 Grease NOTE:
Bearing cones, rollers, and cups must be
Special Tools replaced as a set. It can be necessary to
(Ref. CSPSPM) install a different bearing spacer (shim)
Item Nomenclature when you replace upper bearing.
T909 Upper Seal Tool, Hub
It is not necessary to replace grease on
bearing and in spaces if it is not past its
A. Upper Seal Removal life limit.
Grease (C104)
(1). Remove hub retention nut and nut
retainer (ref. Main Rotor Hub Remov
al).
(2). Remove upper seal (6) and discard. Use

seal puller or other applicable proce (1). Remove upper seal.
dure.
(2). Remove upper seal stop (8).
B. Upper Seal Installation
(3). Remove grease from space above upper
Grease (C104) bearing (1).
Always wear rubber or clean

CAUTION fabric gloves when you handle
bearing to prevent contamination of bearing
with oil from your skin.
(1). Make sure space above bearing is full to
the top edge of bearing cone with NOTE: Use upper bearing removal tool (T907)
grease (C104). if the hub is installed on rotorcraft.
(2). Make sure upper seal stop is installed. (4). Put two upper bearing removal tool
(T907) (15) below lip of bearing cone (2)
(3). Install new upper seal and press into between bearing rollers (3) and lift
position, use hub upper seal tool (T909). bearing (1).
Page 417
B. Upper Bearing Installation 19. Lower Seal, Upper Hub Assembly

(Ref. Figure 406)
Always wear rubber or clean
CAUTION fabric gloves when you handle
bearing to prevent contamination of bearing Consumable Materials
with oil from your skin. (Ref. CSPSPM)
Item Nomenclature
NOTE: C104 Grease
C310 Primer
If you replace bearing, record serial num
ber of new bearing in rotorcraft log book.
Special Tools
Bearing cones, rollers, and cups must be (Ref. CSPSPM)
replaced as a set. It can be necessary to Item Nomenclature
install a different bearing spacer (shim) T911 Lower Bearing Seal and Outer Race
when you replace upper bearing. Installation Tool, Hub
Fill bearing with grease by hand, use
force to push grease into bearing. Do no A. Lower Seal Removal
put too much grease in bearing.
(1). Remove main rotor hub (Ref. Main
If you use a bearing grease tool, use mini Rotor Hub Removal).
mum pressure to make sure sufficient
(2). Remove upper bearing.
grease goes into bearing.
(3). Remove hub shim (13).
Grease (C104) (4). Put hub top down on work bench.
If older two piece seal (with re
CAUTION tainer) is installed, it can be nec
essary to be deform seal to remove. Do not
damage hub.
(1). Fill bearing with grease, use grease (5). Remove lower seal (9) and discard. Use
(C104). seal puller or other applicable proce
dure.
Make sure all hub spaces are
CAUTION filled with grease to prevent B. Lower Seal Installation
condensation. Grease (C104)
(2). Fill space between center seal and

upper bearing cup with grease (C104).
(3). Install bearing. Make sure bearing (1). Make sure space between bearing and
rollers fully touch bearing cup. seal is full of grease to the top edge of
bearing cone, use grease (C104).
(4). Fill space above bearing to top of Primer (C310)
bearing cone with grease (C104).
(5). Install upper seal stop.
(6). Install new upper seal. (2). Apply primer (C310) to mating surface
of lower seal.
18. Shim, Upper Hub Assembly (3). Install lower seal in hub, use hub lower
bearing seal and outer race installation
(Ref. Lower Bearing Removal and Installation) tool (T911). Install while primer is wet.
Page 418
(4). Turn hub top up. Grease (C104)
(5). Install hub shim.
(6). Install upper bearing.

NOTE: It is not necessary to replace grease on
bearing and in spaces if it is not past its life
(7). Install main rotor hub (ref. Main Rotor
limit.
Hub Removal).
(2). Remove lower bearing (10)/hub liner
20. Liner, Main Rotor Hub (11) assembly.
(3). Separate lower bearing from liner, use
(Ref. Lower Bearing Removal and Installation) hub lower bearing liner tool (T910) .
B. Lower Bearing Installation
21. Lower Bearing, Upper Hub Assembly
NOTE:
(Ref. Figure 406) Bearing cones, rollers, and cups must be
replaced as a set.
Always wear rubber or clean fabric gloves
Consumable Materials when you touch bearing to prevent con
(Ref. CSPSPM) tamination of bearing with oil from your
Item Nomenclature skin.
C104 Grease Fill bearing with grease by hand, use
force to push grease into bearing. Do no
put too much grease in bearing.
Special Tools
(Ref. CSPSPM) If you use a bearing grease tool, use mini
Item Nomenclature mum pressure to make sure sufficient
grease goes into bearing.
T910 Lower Bearing Liner Tool, Hub
Grease (C104)
A. Lower Bearing Removal
NOTE:
(1). Fill lower bearing with grease (C104).
replaced as a set. (2). Install lower bearing on hub liner, use
hub lower bearing liner tool (T910).
Make sure all hub spaces are
when you touch bearing to prevent con CAUTION filled with grease to prevent
tamination of bearing with oil from your
skin. condensation.
(3). Fill space between center seal and
(1). Remove lower seal. lower bearing cup with grease (C104).
Page 419
(4). Install lower bearing with liner into B. Upper Bearing Cup Installation
hub.
NOTE:
(5). Install lower seal. Bearing cones, rollers, and cups must be
replaced as a set. It can be necessary to
install a different bearing spacer (shim)
22. Upper Bearing Cup (Outer Race), Upper when you replace upper bearing.
Hub Assembly
(Ref. Figure 406)
when you touch bearing to prevent con
Consumable Materials tamination of bearing with oil from your
(Ref. CSPSPM) skin.
Item Nomenclature
(1). Measure and record outer diameter of
C104 Grease bearing cup, use 6 - 7 in. outside
micrometer (T2020).
Special Tools (2). Measure and record inner diameter of
(Ref. CSPSPM) upper hub where cup will be installed,
Item Nomenclature use 2 - 6 in. dial bore gage (T2021).
T912 Upper Bearing Outer Race Installation
Tool, Hub Bearing cup outer diameter
CAUTION must be between 0.006 and
T917 Race Removal Tool
0.009 inch (0.15 and 0.23 mm) larger than
T2018 Press, Hydraulic upper hub inner diameter.
T2020 Micrometer, Outside, 6 7 In.
(3). Record the difference between the two
T2021 Dial Bore Gage, 2 6 In. measurements.
(4). Cool bearing cup in dry ice or freezer for

A. Upper Bearing Cup Removal a minimum of 5 minutes.
(5). Put cooled bearing cup in liquid

NOTE: nitrogen for a minimum of 10 minutes.
(6). Heat upper hub to a maximum temper
replaced as a set. It can be necessary to
ature of 2005F (93.35C).
install a different bearing spacer (shim)
when you replace upper bearing. Grease (C104)
skin.
(7). Apply a thin layer of grease (C104) to
(1). Remove lower bearing. inner diameter of upper hub where
bearing cup will be installed.
(2). Put race removal tool (T917) below (8). Install bearing cup in upper hub, use
bottom of upper bearing cup (5) and hub upper bearing outer race installa
tighten. tion tool (T912). Make sure bearing cup
is fully installed, apply a 500 lb (227
(3). Push bearing cup out of hub, use kg) force on bearing cup until cup is at
hydraulic press (T2018). room temperature.
Page 420
(9). Install lower bearing. A. Lower Bearing Cup Removal

NOTE:
23. Center Seal, Upper Hub Assembly
(Ref. Figure 406) replaced as a set.
Special Tools
(Ref. CSPSPM)
skin.
Item Nomenclature
T914 Center Seal Tool, Hub (1). Remove lower bearing.
(2). Put race removal tool (T917) below
A. Center Seal Removal bottom of lower bearing cup (5) and
tighten.
NOTE: Unless center seal is damaged, it does (3). Push bearing cup out of hub, use
not need to be removed during an overhaul. hydraulic press (T2018).
(1). Remove upper bearing cup. B. Lower Bearing Cup Installation
(2). Remove center seal (12) and discard. NOTE:

Use hub center seal tool (T914). Bearing cones, rollers, and cups must be
replaced as a set.
B. Center Seal Installation
(1). Install new center seal, use hub center
seal tool (T914). Always wear rubber or clean fabric gloves
(2). Install upper bearing cup. tamination of bearing with oil from your
skin.
24. Lower Bearing Cup (Outer Race), Upper (1). Measure and record outer diameter of
Hub Assembly bearing cup, use 6 - 7 in. outside
micrometer (T2020).
(Ref. Figure 406)
(2). Measure and record inner diameter of
upper hub where cup will be installed,
Consumable Materials use 2 - 6 in. dial bore gage (T2021).
(Ref. CSPSPM)
Item Nomenclature Bearing cup outer diameter
CAUTION must be between 0.006 and
C104 Grease
0.009 in. (0.15 and 0.23 mm) larger than
upper hub inner diameter.
Special Tools
(Ref. CSPSPM) (3). Record the difference between the two
Item Nomenclature measurements.
T911 Lower Bearing Seal and Outer Race
(4). Cool bearing cup in dry ice or freezer for
Installation Tool, Hub
a minimum of 5 minutes.
T917 Race Removal Tool
T2018 Press, Hydraulic (5). Put cooled bearing cup in liquid
T2020 Micrometer, Outside, 6 7 In.
nitrogen for a minimum of 10 minutes.
T2021 Dial Bore Gage, 2 6 In. (6). Heat upper hub to a maximum temper
ature of 2005F (93.35C).
Page 421
Grease Grease (C104)
(7). Apply a thin layer of grease (C104) to

inner diameter of upper hub where (1). Clean bearings (1 and 10) (ref. CSP-
bearing cup will be installed. SPM) and apply a thin film of grease
(C104).
(8). Install bearing cup in upper hub, use
hub lower bearing seal and outer race (2). Assemble upper hub (14), center seal
installation tool (T911). Make sure (12), lower bearing (10)/hub liner (11)
bearing cup is fully installed, apply a assembly, main rotor hub shim (13),
500 lb (227 kg) force on bearing cup and upper bearing (1).
until cup is at room temperature.
(3). Use hub bearing preload tool (T915)
(9). Install lower bearing. and hydraulic press (T2018) to evenly
apply 4000 lb (1814 kg) of force on
25. Bearing Shim Selection, Upper Hub upper bearing, while you continuously
Assembly turn hub counterclockwise by hand.
(Ref. Figure 406 and Figure 407) (4). Decrease force to 500 lb (226.75 kg).
This procedure finds the correct thickness of (5). Continuously turn hub counter-clock
main rotor hub shim. The correct shim makes wise by hand until pressure gauge on
sure the load on upper hub bearings is correct hydraulic press (T2018) is stable.
when hub is installed on the rotorcraft.
(6). Turn hub one half (1/2) turn clockwise.
Special Tools
(7). Measure force necessary to continuous
(Ref. CSPSPM)
ly turn hub one quarter (1/4) turn
Item Nomenclature
counter-clockwise, use digital pull gage
T915 Bearing Preload Tool, Hub (T2023). Apply force 90 degrees from
T2018 Press, Hydraulic hub center line.
T2023 Pull Gage, Digital
NOTE:
As bearing load increases, force to turn
NOTE: hub will increase until bearing is at full
It is necessary to use a hydraulic press load.
(T2018) that can provide a force of 0 to
At full bearing load, force to turn hub will
10,000 lb (0 to 4535.15 kg) with a cali
not increase when more force is applied to
brated pressure gauge for hub shim selec
bearing.
tion.
With correct shim, full bearing load will
Start with same shim thickness as shim
occur between 1500 and 2000 lb (680.27
removed from hub assembly or the middle
thickness shim. and 907.02 kg).
Always wear rubber or clean fabric gloves (8). Repeat steps (5). thru (7). for forces of
when you touch bearing to prevent con 1000 lb (453.51 kg), 1500 lb (680.27
tamination of bearing with oil from your kg), 2000 lb (907.02 kg), 2500 lb
skin. (1133.78 kg) and 3000 lb (1360.54 kg).
Page 422
NOTE: turn hub must not be more than force

If force to turn hub continually increased to turn hub with 2000 lb (907.02 kg)
while force on bearing increased thru force on bearing as measured in step
1500 lb (680.27 kg), and did not increase (8). and must be between 3.5 and 5.0
above 2000 lb (907.02 kg) go to Step (9). lb (1.59 and 2.27 kg).
If force to turn hub did not increase thru (10). If force to turn hub with 6000 lb
1500 lb (680.27 kg) force on bearing, (2721.08 kg) of force on bearing is more
install the next thinner shim and repeat than with 2000 lb (907.02 kg) of force
steps (3). thru (8). on bearing or is not between 3.5 and
If force to turn hub increased above 2000 5.0 lb (1.59 and 2.27 kg), install a
lb (907.02 kg) force on bearing, install different shim and repeat steps (3).
the next thicker shim and repeat steps thru (9).
(3). thru (8).
(11). Remove bearings, liner, and shim and
(9). To make sure correct thickness shim fully clean.
has been installed, apply 6000 lb
(2721.08 kg) of force on bearing and (12). Record shim part number in hub
measure force to turn hub. Force to assembly component record.
Page 423
26. Identification Plate,Upper Hub Assembly NOTE: Do not install identification plate over
serial number or part number.
(1). Make faying surface of hub rough with
400 grit abrasive paper (C814) or
1 equivalent.
2
(2). Wipe clean with cleaning solvent (C423)
then dry in air for a minimum of 10
minutes.
(3). Apply adhesive in less than 2 hours
after solvent is dry.
TOP VIEW
9G62-066A
1. IDENTIFICATION PLATE
2. APPLY FORCE TO TURN HUB HERE (4). Bond identification plate (16) to hub
Figure 407. Upper Hub Bearing Preload Pull with epoxy adhesive (C407) and edge
Direction and Hub Identification seal.
A. Identification Plate Installation (5). Dry adhesive in air 4 hours.
(Ref. Figure 407) 27. Balance Weight, Hub/Pitchcase

A. Balance Weight Removal
(Ref. CSPSPM) NOTE: Ref Section 18-00-00, Hub Weight/
Item Nomenclature Pitchcase Weight Adjustment
C814 Abrasive Paper
B. Balance Weight Installation
C407 Adhesive, Epoxy NOTE: Ref Section 18-00-00, Hub Weight/
Pitchcase Weight Adjustment
Page 424
5
4
1
3 9G62081B
1. NUT 4. WASHER
2. WASHER 5. BOLT
3. PITCH HORN
Figure 408. Pitch Horn Replacement
28. Pitch Horn (6). If necessary, remove bolts (5) and
washers (4).
Be careful, do not damage pitch
CAUTION case or inside doubler. Do not use chemicals to remove
CAUTION sealant.
NOTE: This task is typical for all pitch horns.
(7). Remove sealant from the mating
A. Pitch Horn Removal surface of the pitchcase and pitch horn.
(Ref. Figure 408) B. Pitch Horn Installation
(1). Disconnect pitch link from pitchcase (Ref. Figure 408)

(2). Remove sealant from nuts (1). (Ref. CSPSPM)
Item Nomenclature
(3). Remove lockwire.
(4). Remove sealant from pitch horn (3). C702 Lockwire
(5). Remove nuts (1), washers (2), and pitch
horn (3). (1). Do a fit check of new pitch horn (3).
Page 425
(a). Make sure the bolt holes of pitch (b). Safety nuts (1) with lockwire (C702).
horn (3) and the pitchcase align at all
4 places. Sealing Compound (C211)
(2). If removed, install washers (4) on bolts

(5).
(5). Environmentally seal pitch horn (3),
bolts (5), nuts (1), and lockwire with
SPM).
(3). Install bolts (5) wet with sealing (6). If necessary, touch up paint with
compound (C211). Dupont Imron 5000, or 6000 polyure
thane color number, 17925 (FED-
(4). Install washers (2) and nuts (1). STD-595) (ref. CSP-SPM).
(a). Torque nuts (1) 30 to 40 in-lb (3.39 (7). Connect pitch link to pitchcase (ref.
to 4.52 Nm). Section 62-30-00).
Page 426

INSPECTION/TEST
1. Main Rotor Hub Assembly (c). Examine top surface of upper hub
(Figure 801) for corrosion.
A. Main Rotor Hub Assembly Inspection
(Area 4) 1). If there is corrosion, repair upper
hub (ref. Repair, Upper Hub
(Ref. Figure 601) Upper Surface Corrosion).
Do not move the rotor blade tip (4). Examine main rotor hub (1) for nicks
CAUTION up more than 4.0 ft. (1.22 m) and scratches. None permitted (ref.
when the rotor is not in operation. And do Repair, Hub Small Nick and Scratch).
not move the flexbeam up more than 1.0 in. (5). Examine main rotor hub (1) for loose or
(2.54 cm) at the blade attach point. Dam missing lockwire and cotter pins.
age to the flexbeam can occur. Replace if loose or missing.
NOTE: Examine all components for condition (6). Examine nuts (2) for loss of torque
and/or unusual wear. If a component has an (broken torque stripe). Torque loose
indication of unusual wear or you are not flexbeam nuts.
sure of its condition, replace the component.
(7). Examine upper and lower damper caps
(1). Disassemble main rotor hub assembly (3, 4) for cracks and correct installation.
(1) for inspection. No cracks or incorrect installation
permitted.
(2). Examine main rotor hub (1) for cracks.
(8). Examine lower damper caps (4) for a
NOTE: Make sure the areas adjacent to the maximum wear of 0.020 inch (0.51
bolts of the upper and lower hubs are fully mm) where droop stop roller (13)
examined for cracks. contacts damper cap (4).
NOTE: Particles of rubber are an indication of
damper separation.
(3). Examine main rotor hub (1) for corro (9). Examine upper and lower dampers (5)
sion as follows: for separation. None permitted.
(a). Examine flexbeam pockets (2, (a). Torque or replace loose or missing
Figure 802) for corrosion. hardware.
1). If there is corrosion, repair the NOTE:

lower hub or upper hub (ref. Elastomeric material surface cracks are
Repair, Flexbeam Pockets and permitted over all of the centering
Hub Mating Surfaces Corrosion). bearing.
Black powder is an indication of a light
(b). Examine the mating surfaces of
deterioration of the elastomeric material
upper hub (3, Figure 802) and lower
and is permitted.
hub (4, Figure 802) for corrosion,
cracks, and damage. If the housing is not aligned with the cen
ter bushing, it is an indication of center
1). Replace a lower hub or upper hub ing bearing separation.
with cracks or damage. Particles of rubber are an indication of
separation.
2). If there is corrosion, repair the
lower hub or upper hub (ref. (10). Examine centering bearings (6) for
Repair, Flexbeam Pockets and separation between elastomeric
Hub Mating Surfaces Corrosion). material and housing. None permitted.
Page 601
(a). Torque or replace loose or missing 1). The radial play cannot be more
hardware. than 0.050 inch (1.27 mm)
maximum.
(11). Examine centering bearing housing for
cracks. None permitted. (d). Replace rollers (13) with damage,
unwanted movement, or radial play
(12). Examine pitchcase (7) for cracks. None
more than permitted.
permitted.
(13). Examine inner surfaces of pitchcase (7) (e). Examine rollers (13) for correct
for unwanted material. None per installation. Torque or replace loose
mitted. or missing hardware.
(14). Examine droop stop striker plate (11) (18). Examine drive ring (14) for cracks and
for cracks and correct installation. No correct installation. No cracks or
cracks or incorrect installation per incorrect installation permitted.
mitted.
(a). Torque or replace loose or missing
(a). Torque or replace loose or missing hardware.
hardware.
(19). Examine grounding jumpers (15 and
(15). Examine droop stop striker plate for 16) for broken wires and correct
wear where roller touches plate. installation. No broken wires or
Maximum wear 0.100 inch (2.54 mm). incorrect installation permitted.
(16). Examine droop stop supports (12): (a). Torque or replace loose or missing
(a). Examine supports (12) for condition. hardware.
(b). Examine supports (12) for cracks in (20). Examine ground brush holder (17) for
the upper bend area. correct installation. Torque or replace
loose or missing hardware.
(c). Replace supports (12) with damage
or cracks in the upper bend area. (21). Examine ground brush (18) for wear.
Minimum length 0.375 inch (9.52 mm).
(d). Make sure that components are
correctly attached. B. Identification/Data Plate Inspection
(e). Torque or replace loose or missing NOTE:
hardware.
The plate location is on top of the main ro
(17). Examine droop stop rollers (13) of lower tor hub assembly.
damper cap assemblies (4): Plates show current configuration of hub
(a). Examine rollers (13) for damage. assembly must agree with data recorded
in the rotorcraft log book.
(b). Make sure rollers (13) move freely.
(1). Make sure plates are tightly attached.
(c). Measure the radial play of rollers
(13). (2). Make sure you can read plates.
Page 602
10
7
3 15
9
1
5 17 18
2 (NOTE 2) 5
14 VIEW ROTATED
NOTE 1 6
16
5
NOTE 3
NOTE 3
12 REF 6
4
5
13 5
11
12 NOTE 3
REF. 14
NOTES:
1. UPPER BEND AREA.
2. REFER TO FLEXBEAM INSTALLATION FOR TORQUE PROCEDURE.
3. EXAMINE ELASTROMERIC MATERIAL FOR DETERIORATION.
9G62013D
1. MAIN ROTOR HUB 10. FLEXBEAM BUMPER
2. FLEXBEAM NUT 11. STRIKER PLATE, DROOP STOP
3. UPPER DAMPER CAP 12. DROOP STOP SUPPORT
4. LOWER DAMPER CAP 13. DROOP STOP ROLLER
5. DAMPER 14. DRIVE RING
6. CENTERING BEARING 15. GROUNDING JUMPER
7. PITCHCASE 16. GROUNDING JUMPER
8. ROTOR BLADE 17. GROUNDING BRUSH HOLDER
9. FLEXBEAM 18. GROUND BRUSH
Figure 601. Main Rotor Hub Assembly
Page 603
C. Flexbeam Inspection (Area 4) (2). Inspect the areas of the flexbeam that
you can access for delamination (fiber
(Ref. Figure 602) fuzz, separation, breakage).
(3). EARLY CONFIG - Inspect the top and
Consumable Materials bottom of the flexbeam where lead and
(Ref. CSPSPM) lag legs join. Maximum crack length 2.0
Item Nomenclature in. (5.08 cm).
C432 Cleaner
NOTE: Ref. Service Bulletin SB900-001 (most
current revision), for ferry flight permitted
limits.
Special Tools
(4). Inspect the top and bottom of the shear
(Ref. CSPSPM)
web surface for surface cracks. None
Item Nomenclature
permitted.
T906 Borescope
(5). EARLY CONFIG - Inspect the leading
and trailing edges of the flexbeam and
Cleaner (C432) flexbeam legs for a visible separation
between the flexbeam laminates and
shear web. Maximum separation 1.0 in.
(2.54 cm) in specified areas only.
(6). CURRENT CONFIG - Inspect the
Do not move the rotor blade tip wrapped part of the flexbeam and
CAUTION up more than 4.0 ft. (1.22 m) flexbeam legs for a visible separation
when the rotor is not in operation. And do between the flexbeam and wrap.
Visible cracks of the resin along the
edges of the wrap is permitted.
Maximum crack in the legs 1.00 in.
NOTE: (25.4 mm).
Flexbeam inspection intervals are differ No loose wrap permitted.
ent for different flexbeams. Ref. Section
05-20-10 for inspection interval by part (7). Inspect the flexbeam bumper for
number. deterioration and cracks. No damage
permitted.
If a borescope is not available, you must
remove the main rotor pitchcase to in (8). Inspect edges of flexbeam between 1.0
spect the flexbeam. in. and 2.0 in. inboard of blade attach
If you are not sure of the borescope or hole center for nicks. Maximum depth
visual indications, remove the pitchcase. 0.020 in. (0.508 mm) with no fiber
damage permitted. Break sharp edges
Support the main rotor blade during the and fill with a resin wash.
inspection. Have one person on a mainte
nance stand. (9). Inspect shear web between 1.0 in. and
2.0 in. inboard of blade attach hole
(1). Use cleaner (C432) to clean the flex center for nicks. Break sharp edges and
beam before inspection. fill with a resin wash.
Page 604
NOTE 9 2.0 IN (5.08 cm)

1.0 IN (2.54 cm)
BUMPER ASSEMBLY
NOTE 8
NOTE 4
SHEAR WEB
LEAD LEG
SHEAR WEB
ATTACH POINT SHEAR WEB SURFACE

NOTE 7
LAG LEG NOTE 3
NOTE 9 2.0 IN (5.08 cm)

NOTE 2 1.0 IN (2.54 cm)
ATTACH POINT
EARLY CONFIG FIBERGLASS WRAP

BUMPER ASSEMBLY
NOTE 8
NOTE 3 NOTE 5
LEAD LEG
FIBERGLASS WRAP NOTE 1 NOTE 12 SHEAR WEB
NOTE 1
ATTACH
POINT SHEAR WEB SURFACE
NOTE 7
LAG LEG
NOTE 1
NOTE 2
NOTE 6 WRAPPED CONFIG
NOTE 2 ATTACH
POINT 9G62-048G
NOTES:
1. VISIBLE SEPARATION OF THE WRAPS ALONG EACH SIDE OF THE LEGS OR ALONG EACH SIDE OF THE MAIN BODY OF THE FLEXBEAM IS
PERMITTED. NO SINGLE OR COMBINED SEPARATION LONGER THAN 1.0 IN. (2.54 cm) IS PERMITTED ON EACH SIDE.
2. DISREGARD INDICATIONS OF SEPERATION IN THIS AREA UNDER THE INBOARD END OF THE SHOES.
3. 1 IN (2.54 cm) MAXIMUM SEPERATION.
4. 2 IN (5.08 cm) MAXIMUM CRACK (TOP OR BOTTOM).
5. VISIBLE FISSURES IN THE RESIN/SEALANT ALONG OR UNDER THE FLEXBEAM BRIDGE ARE PERMITTED. THEY CAN BE FILLED WITH A RESIN WASH
6. CRACKING OF SEALANT ALONG INSIDE EDGE OF UNWRAPPED AREA IS PERMITTED.
7. NO SHEAR WEB SURFACE CRACKS PERMITTED. BREAK SHARP EDGES OF NICKS IN SHEAR WEB AND FILL WITH A RESIN WASH.
8. NO BUMPER ASSEMBLY DETERIORATION, SUCH AS PERMANENT COMPRESSION, DEFORMATION, TEARS, OR CRACKS PERMITTED.
9. NICKS ON EDGE OF FLEXBEAM OF 0.20 IN (0.508 mm) MAXIMUM DEPTH, WITH NO FIBER DAMAGE ARE PERMITTED.
BREAK SHARP EDGES AND FILL WITH A RESIN WASH.
10. A LOOSE OR BROKEN WRAP THAT CAN BE LIFTED UP ALONG AN EDGE IS CAUSE FOR REJECTION.
11. MANUFACTURING FOLDS OR WRINCKLES IN THE WRAP CAN APPEAR TO BE FIBER SEPARATION OR BREAK. CLOSE EXAMINATION IS NECESSARY
TO DETERMINE WHETHER THE INDICATION IS A FIBER SERARATION OF A FOLD. A FOLD CAN APPEAR AS AN ACCUMULATION OF RESIN. A FOLD OR
WRINKLE IS PERMITTED, BUT A FIBER SEPARATION OR BREAK IS NOT.
12. DARK LINES THAT INDICATE GAPS BETWEEN THE EDGE OF ONE WRAP AND THE EDGE OF THE NEXT WRAP ARE NORMAL AND PERMITTED.
Figure 602. Flexbeam Inspection
Page 605
NOTE 10 2.0 IN (5.08 cm)

1.0 IN (2.54 cm)
LEAD LEG
NOTE 1 SHEAR WEB
FIBERGLASS WRAP
NOTE 1
NOTE 1
FIBERGLASS WRAP
BUMPER ASSEMBLY
NOTE 7
ATTACH
POINT
NOTE 5 LAG LEG

NOTE 1
ATTACH
POINT FULLY WRAPPED (CURRENT) CONFIG
NOTE 5
NOTE 4 NOTE 3 FLEXBEAM BRIDGE
OUTBOARD
NOTE 6
LATERAL
NOTE 2
APEX
NOTE 4
NOTES:
1. VISIBLE SEPARATION OF THE WRAPS ALONG EACH SIDE OF THE LEGS OR ALONG EACH SIDE OF THE MAIN BODY OF THE FLEXBEAM IS
PERMITTED. NO SINGLE OR COMBINED SEPARATION LONGER THAN 1.0 INCH.(2.54 CM) IS PERMITTED ON EACH SIDE.
2. VISIBLE FISSURES IN THE RESIN ARE PERMITTED IN THE WRAPS BETWEEN THE APEX AND THE FLEXBEAM BRIDGE. THEY CAN BE FILLED WITH A
RESIN WASH TO PREVENT COLLECTION OF MOISTURE.
3. VISIBLE FISSURES IN THE RESIN/SEALANT ALONG OR UNDER THE FLEXEAM BRIDGE ARE PERMITTED. THEY CAN BE FILLED WITH A RESIN WASH.
4. A SEPARATION (SPLIT) EXTENDING OUTBOARD FROM THE APEX IS NOT PERMITTED IF IT IS VISIBLE BEYOND THE FLEXBEAM BRIDGE.
5. DISREGARD INDICATIONS OF SEPARATION IN THIS AREA UNDER THE INBOARD END OF SHOES.
6. DARK LINES INDICATING GAPS BETWEEN THE EDGE OF ONE WRAP AND THE EDGE OF THE NEXT WRAP ARE NORMAL AND PERMITTED.
7. NO BUMPER ASSEMBLY DETORIORATION, SUCH AS PERMAMENT COMPRESSION, DEFORMATION, TEARS OR CRACKS PERMITTED.
8. A LOOSE OR BROKEN WRAP THAT CAN BE LIFTED UP ALONG AN EDGE IS CAUSE FOR REJECTION.
9. MANUFACTURING FOLDS OR WRINKLES IN THE WRAPS CAN APPEAR TO BE FIBER SEPARATION OR BREAK. CLOSE EXAMINATION IS NECESSARY TO
DETERMINE WHETHER THE INDICATION IS A FIBER SEPARATION OR A FOLD. A FOLD CAN APPEAR AS AN ACCUMULATION OF RESIN. A FOLD OR
WRINKLE IS PERMITTED, BUT A FIBER SEPARATION OR BREAK IS NOT.
10. NICKS ON EDGE OF FLEXBEAM OF 0.20 IN (0.508 mm) MAXIMUM DEPTH, WITH NO FIBER
DAMAGE ARE PERMITTED. BREAK SHARP EDGES AND FILL WITH A RESIN WASH. 9G62-090A
Figure 602. Flexbeam Inspection (Cont.)
Page 606
D. Upper Seal Inspection (Area 4) Solvent, Cleaning (C421)

(Ref. Figure 603)
NOTE:
If you remove upper seal, you must dis (2). Remove grease from bearing, use
card it. cleaning solvent (C421).
Removal of rotor hub is not necessary for
(3). Remove grease from bearing cup (5).
upper seal inspection.
(4). Examine bearing rollers (3), bearing
(1). Examine upper seal (6) for cuts, cracks, cage (4), bearing cup (13), and bearing
or deformation. No damage permitted. cone (20) for cracks, scores, and heat
(2). Examine upper seal (6) for indications damage. None permitted.
of grease leakage. None permitted. (5). Examine bearing rollers and bearing
cup for scratches:
Grease (C104)
(a). Small surface scratches on non-wear
surfaces with no metal movement,
are permitted.
(b). Maximum depth for a scratch is
(3). With the nut retainer removed (Ref. 0.010 in. (0.254 mm).
Main Rotor Assembly Removal), feel
with your finger under lip of upper seal (6). Make sure bearing rollers are correctly
to make sure seal spring (7) is installed installed in bearing cage.
and has no deformations.
(7). Examine bearing rollers and bearing cup
E. Upper Bearing Inspection (Area 4) for corrosion:
(Ref. Figure 603) (a). Maximum quantity of locations for

corrosion on non-wear surfaces is four.
Consumable Materials (b). Each location dimension can not be
(Ref. CSPSPM) more than 0.050 in. (1.27 mm) in a
Item Nomenclature 0.250 in. (6.35 mm) area.
C104 Grease (c). A depth less than 0.015 in. (0.381
C421 Solvent, Cleaning mm) is permitted.
(d). No corrosion permitted on other
Always wear rubber gloves surfaces.
CAUTION when you hold the bearing. This
prevents contamination of the bearing with (8). Examine bearing rollers and bearing
the oil in your skin. cup for blue color. None permitted.
(9). Examine bearing rollers for flat areas.
NOTE: The non-wear surfaces are top and bot
tom surfaces of bearing cone and top and None permitted.
bottom surface of bearing cup. (10). Examine bearing cup for dents:
Grease (C104) (a). A maximum dent dimension of 0.010
in. (0.254 mm) on bearing cup
non-wear surfaces is permitted.
(b). No dents permitted in other areas.
(1). Remove bearing (1) (Ref. Upper (11). Examine bearing rollers and bearing
Bearing Removal). cup for spalling. The maximum spall
Page 607
dimension permitted in one direction is Always wear rubber gloves

0.025 in. (0.635 mm). CAUTION when you hold the bearing. This
prevents contamination of the bearing with
NOTE: the oil in your skin.
Abrasive wear is permitted if can not be
NOTE:
felt and no bearing noise can be heard.
The non-wear surfaces are top and bot
True brinelling is caused by heavy impact tom surfaces of bearing cone and top and
loads from rollers to cup. An indication of bottom surface of bearing cup.
true brinelling is metal deformation.
You must remove the lower bearing to do
(12). Examine bearing rollers and bearing the inspection.
cup for true brinelling. Maximum
Grease (C104)
permitted 0.015 in. (0.381 mm) in
width and 0.030 in. (0.762 mm) in
length.
(13). Examine upper seal (6) contact surface
of the main rotor hub nut retainer (7, (1). Remove lower bearing (12) (Ref. Lower
Figure 401) for cracks, sharp nicks, or Bearing Removal).
metal movement. None permitted.
(a). Corrosion or other surface damage
can be removed. Maximum depth
after repair 0.004 in. (0.101 mm)
(Ref. CSP-SPM).
(2). Remove grease from bearing, use
Grease (C104) cleaning solvent (C421).
(3). Remove grease from bearing cup (13).
(4). Examine bearing rollers (21), bearing
cage (22), bearing cup (13), and bearing
(14). Apply a thin film of grease (C104) to cone (20) for cracks, scores and heat
bearing and bearing cup to protect from damage. None permitted.
corrosion.
(5). Examine bearing rollers and bearing
F. Lower Seal Inspection (Area 4) cup for scratches:
(Ref. Figure 603) (a). Small surface scratches on non-wear

surfaces with no metal movement,
NOTE: If you remove the seal, you must dis are permitted.
card it. (b). Maximum depth for a scratch is
(1). If lower seal is in hub, inspect for 0.010 in. (0.254 mm).
condition and indications of grease (6). Make sure bearing rollers are correctly
leakage. installed in bearing cage.
G. Lower Bearing Inspection (Area 4) (7). Examine bearing rollers and bearing
cup for corrosion:
(Ref. Figure 603)
(a). Maximum quantity of locations for
corrosion on non-wear surfaces is four.
(Ref. CSPSPM) (b). Each location dimension can not be
Item Nomenclature more than 0.050 in. (1.27 mm) in a
C104 Grease 0.250 in. (6.35 mm) area.
C421 Solvent, Cleaning (c). A depth less than 0.015 in. (0.381
mm) is permitted.
Page 608
(d). No corrosion permitted on other permitted 0.015 in. (0.381 mm) in

surfaces. width and 0.030 in. (0.762 mm) in
length.
(8). Examine bearing rollers and bearing
cup for blue color. None permitted. H. Center Seal Inspection (Area 4)
(9). Examine bearing rollers for flat areas. (Ref. Figure 603)
None permitted.
(10). Examine bearing cup for dents:
NOTE:
You must remove hub liner to do the cen
(a). A maximum dent dimension of 0.010 ter seal inspection.
in. (0.254 mm) on bearing cup
non-wear surfaces is permitted. Unless center seal has damage, do not re
move center seal.
(b). No dents permitted in other areas.
If you remove center seal, you must dis
(11). Examine bearing rollers and bearing card it.
cup for spalling. The maximum spall
dimension permitted in one direction is (1). Examine seal (9) for condition and
0.025 in. (0.635 mm). correct installation.
NOTE: I. Lead/Lag Leg Shim Inspection (Area 4)

Abrasive wear is permitted if it can not be (Ref. Figure 603)
felt and no bearing noise can be heard.
True brinelling is caused by heavy impact (1). Examine lead leg and lag leg shims (18
loads from rollers to cup. An indication of and 19) for condition and correct
true brinelling is metal deformation. installation.
(12). Examine bearing rollers and bearing (2). Make sure shims did not move up or
cup for true brinelling. Maximum overlap on sides of hub.
Page 609
2
6 1 18 (5 PL)

7
VIEW ROTATED
LOOKING UP
5
8
11
14
16 19 (5 PL)
9
15
17
13
12
21
22
10
20 VIEW ROTATED
LOOKING DOWN
9G62025D
1. UPPER BEARING 12. LOWER BEARING
2. UPPER BEARING CONE 13. LOWER BEARING CUP
3. UPPER BEARING ROLLER 14. HUB (CENTER) PLATE
4. UPPER BEARING CAGE 15. FLEXBEAM POCKET
5. UPPER BEARING CUP 16. LOWER HUB HALF
6. UPPER BEARING SEAL 17. HUB LINER
7. UPPER BEARING SEAL SPRING 18. LEAD SHIM (UPPER)
8. UPPER BEARING SEAL STOP 19. LAG SHIM (LOWER)
9. CENTER SEAL 20. LOWER BEARING CONE
10. LOWER BEARING SEAL 21. LOWER BEARING ROLLER
11. UPPER HUB HALF 22. LOWER BEARING CAGE
Figure 603. Main Rotor Hub Inspection
Page 610
2. Main Rotor Hub Special Inspections (2). Examine upper surface of main rotor
upper hub surface for corrosion. None
A. Main Rotor Upper Hub Web Inspection permitted.
(Ref. Figure 604)
Make sure paint stripper and
(1). Examine main rotor upper hub (1) web CAUTION solvent does not go into upper
areas (2) for cracks. No cracks per bearing and grease seal area.
mitted.
(2). Remove paint from web areas (2). Use (3). If necessary, remove paint from bolt
paint removal chemical procedure (ref. holes (3) and bolt hole upper chamfer.
CSP-SPM). Use paint removal chemical procedure
(ref. CSP-SPM).
(3). If you are not sure of the results of a
visual inspection, do the Main Rotor (4). Examine bolt holes (3) for cracks, use a
Hub Eddy Current Inspection. 10X magnifying glass. No cracks
permitted.
(4). Apply primer (C308) and white finish
enamel (C302). Use Paint Repair
procedure (ref. CSP-SPM). (5). Examine chamfer at top of bolt holes (3)
for cracks with a 10X magnifying glass.
B. Main Rotor Upper Hub Flange Inspection No cracks permitted.
(Ref. Figure 604)
(1). Remove main rotor drive plate (ref. visual inspection, do the Main Rotor
Section 63-10-00). Hub Eddy Current Inspection.
3 (10 PL)
2
(5 PL)
VIEW LOOKING DOWN AT TOP OF UPPER HUB
(DRIVE PLATE REMOVED)
9G62014C
1. MAIN ROTOR UPPER HUB 3. BOLT HOLES
2. MAIN ROTOR UPPER HUB WEB AREA
Figure 604. Main Rotor Upper Hub Inspection
Page 611
1 (5 PL)
2 (5 PL)
9 (10 PL) 3
8
5
REF. 4
6
REF. 7
9G62026G
1. RIB 7. CENTERING BEARING

2. FILLET 8. MAIN ROTOR UPPER HUB
3. PITCHCASE 9. BOLT HOLE AREA
4. DAMPER 10. NUT
5. FLEXBEAM 11. PIN
6. PITCH HORN 12. NUT
Figure 605. 100Hour Main Rotor Hub and 50Hour Centering Bearing Inspection
Page 612
C. 100Hour Inspection of the Main Rotor (b). Examine flexbeams (5) for delamina
Hub Assembly tion. None permitted.
(Ref. Figure 605) (4). Examine main rotor upper hub (8) for
cracks at the joint between the five ribs
(1) and upper drive flange, use a 10X
magnifying glass. No cracks permitted.
(Ref. CSPSPM)
Item Nomenclature (5). If you are not sure of the results of a
C432 Cleaner visual inspection, do the Main Rotor
Hub Eddy Current Inspection.
(6). Examine main rotor upper hub between
Special Tools the ribs in the fillet area (2) for cracks
(Ref. CSPSPM) with a 10X magnifying glass. No cracks
Item Nomenclature permitted.
T906 Borescope
visual inspection, do the Main Rotor
(1). Examine main rotor hub assembly with Hub Eddy Current Inspection.
borescope (T906).
(8). Examine area around bolt holes (9) for
(2). Examine pitchcases (3): cracks or wear. None permitted.
(a). Examine inboard and outboard (9). Examine main rotor hub for loose or
machined edges on pitchcases (3) for missing lockwire and cotter pins.
delamination or cracks. Replace if loose or missing.
1). If there is delamination or cracks, (10). Examine nuts (10, 12) for loss of torque
replace pitchcase (3). (broken torque stripe). Torque loose
flexbeam nuts.
(b). Examine inboard edge of pitchcases
(3) immediately above pitch horns (6) (11). Do the Main Rotor Drive Plate Nut
for cracks or separations. Torque Verification (ref. Section
63-10-00).
1). If there are cracks or separation,
replace pitchcase (3). NOTE: Particles of rubber are an indication of
damper separation.
(3). Examine flexbeams (5):
(12). Examine dampers (4) for separation of
Cleaner (C432) the elastomeric material. None per
mitted.
(a). Torque or replace loose or missing
hardware.
(a). If necessary, clean flexbeams (5) with (13). Do Procedure 2.D., 50-Hour Inspec
cleaner (C432). tion for the Center Bearing Assembly.
Page 613
D. 50Hour Inspection for the Center (a). Replace center bearings () with a
Bearing Assemblies separation between the elastomeric
material and housing.
(Ref. Figure 605)
(3). Examine center bearings (7) for
Special Tools separation between the elastomeric
(Ref. CSPSPM) material and center bushing.
Item Nomenclature NOTE:
T906 Borescope
Rubber particles are indication of separa
tion.
(1). Examine center bearings () with If the housing is not aligned with the cen
borescope (T906). ter bushing, it is an indication of center
ing bearing separation.
NOTE: Black powder is an indication of a light
deterioration of the elastomeric material (a). Replace center bearings () with a
and is permitted. separation between the elastomeric
material and center bushing.
(2). Examine center bearings (7) for
separation between the elastomeric (4). Examine center bearings () for cracks.
material and housing.
(a). Replace center bearings () with a
NOTE: crack in the housing.
Rubber particles are indication of separa
tion. (b). Surface cracks in the elastomeric
material are permitted.
If the housing is not aligned with the cen
ter bushing, it is an indication of center (5). Torque or replace loose or missing
ing bearing separation. hardware.
Page 614
Page 615
10 PL
5 PL
5 PL
NOTE 2 (5 PL)
NOTE 1 (5 PL)

CRACK INDICATIONS

2 INCREMENT
SET NORTEC 19 OR EQUIVALENT AS FOLLOWS:
POSITION, HORIZONTAL: 128

POSITION, VERTICAL: 128
NOISE FREQUENCY: 90KHz
GAIN, HORIZONTAL: 52
GAIN, VERTICAL: 73
PHASE: 274
FILTERS:
HI 2
LOW 100
EACH SQUARE = 1 mil
NOTES:
1. NUT, WASHER, AND BOLT REMOVED TO CLEARLY SHOW AREA OF INSPECTION.
2. EXAMINE THE TWO SIDES OF RIB. 9G62028B
Figure 606. Main Rotor Upper Hub Eddy Current Inspection
Page 616
E. Main Rotor Upper Hub Eddy Current NOTE: The upper hub material is forged alumi
Inspection num alloy 7149-T7352.
(Ref. Figure 606)

(4). Set inspection unit for inspection (ref.
manufacturer instructions).
(Ref. CSPSPM)
(5). Null the unit.
Item Nomenclature
C302 Finish Enamel, White
(6). Scan all of the area shown by shadow
C308 Primer on main rotor hub.
C313 Paint Stripper
C425 Solvent, Cleaning NOTE: The probe must be held perpendicular
NA Marker to the surface to be examined.
NA Tape, Teflon
(7). Mark each area on main rotor hub
where there is an unsatisfactory result.
Special Tools
(Ref. CSPSPM) Solvent, Cleaning (C425)
Item Nomenclature
NA Inspection Equipment, Eddy Current
NOTE: Eddy current inspection must be done

by a Level II technician certified by ASNT-
TC-1A, MIL-STD-410, NAS410 or equiva (8). Fully clean marked areas with cleaning
lent in eddy current inspections and have solvent (C425).
done an eddy current inspection in the last
12 months. (9). Carefully scan marked areas again.
Paint Stripper (C313)
(10). If the marked area continues to have
an unsatisfactory result, replace the
upper hub and tell MDHI Field Service
Department.
(1). Remove paint from areas to be inspec

ted with paint stripper (C313) (ref. Finish Enamel, White (C302)
CSP-SPM, 20-40-00, Paint Removal
Chemical).
(2). Put a small piece of Teflon tape on the

tip of the probe to get a smooth result
and prevent wear on the probe. Primer (C308)
(3). Calibrate inspection unit and probe
(ref. manufacturer instructions) to
detect a 0.010 inch (0.25 mm) mini
mum crack.
NOTE: Unit and probe must be calibrated be (11). If the upper hub is good, apply primer
fore inspection, each half hour during in (C308) and white finish enamel (C302)
spection, at the end of inspection, and if a (ref. CSP-SPM, 20-30-00, Main Rotor
cable or probe is changed. Hub).
Page 617
3. Main Rotor Hub Test (1). Move main rotor controls until the top
of upper damper cap (2) is approximate
A. Main Rotor Hub Droop Angle Test ly level with the top of upper hub (1).
(Ref. Figure 607) (2). Measure the droop angle for each rotor
blade.
Special Tools
(a). Put inclinometer (T203) on a flat and
(Ref. CSPSPM)
level surface of upper hub (1) parallel
Item Nomenclature
to pitchcase (2).
T203 Inclinometer
1). Record the angle measurement.
NOTE: (b). Put inclinometer (T203) on the top

surface of upper damper cap (2)
Main rotor blades must be installed.
parallel to pitchcase (4).
The droop angle test is typical for all five
main rotor blades. 1). Record the angle measurement.
It is not necessary to remove the drive (3). The droop angle must be 7.0 to 7.5
plate. degrees at each position.
2 NOTE: The droop angle is the difference be
tween the angle measurement of upper hub
(1) and the angle measurement of upper
1 damper cap (2).
Upper Damper
Hub Cap Droop
Blade Angle Angle Angle
1. =
2. =
3. =
4. =
5. =
3
(4). Add or subtract shims (6) as necessary
to get the correct droop angle (ref.
Removal/Installation procedures for the
droop stop striker plate).
9G62010A (a). Do not install more than three shims

1. UPPER HUB (REF. IPL, 622000, FIG. 1) (6) at each striker plate (5).
2. UPPER DAMPER CAP
3. INCLINOMETER (b). If you cannot get the correct droop
4. PITCHCASE angle, replace worn components (ref.
5. STRIKER PLATE the Inspection and Removal/Installa
6. SHIM
tion procedures for the main rotor
Figure 607. Droop Angle Test hub assembly).
Page 618

REPAIR
1. Repair (6). Apply primer (C308) and white finish
enamel (C302) (Ref. CSP-SPM).
A. Hub Small Nick and Scratch
B. Upper Hub Upper Surface Corrosion
(Ref. Figure 801)
(Ref. Figure 801)
Item Nomenclature
C804 Abrasive Cloth
C804 Abrasive Cloth
C807 Sandpaper
(1). Remove paint from area to be repaired

(1). Remove paint from area to be repaired (ref. CSP-SPM).
(ref. CSP-SPM).
CAUTION
CAUTION
Remove corrosion to a maximum depth of
On machined edges - Remove sharp edges of 0.006 inch (0.15 mm).
nicks to a maximum depth of 0.010 inch You can only repair an area on upper sur
(0.25 mm), length of 0.250 inch (6.35 mm), face of upper hub one time.
and width of 0.125 inch (3.18 mm). No more
than two areas permitted on same edge. (2). Remove corrosion (ref. CSP-SPM).
Minimum between areas 0.250 inch (6.35
mm). (3). Finish removal of corrosion with
600-grit or finer abrasive cloth (C804).
On outer web surfaces - Remove sharp edges
Do not shot peen holes or bores
of nicks to a maximum depth of 0.010 inch CAUTION in main rotor upper hub.
(0.25 mm), length of 0.250 inch (6.35 mm),
and width of 0.125 inch (3.18 mm). No more
(4). Shot peen the full upper mating surface
than three areas permitted. Minimum
of main rotor hub to specification
distance between areas 0.250 inch (6.35
AMS2430 with an intensity of
mm). Remove sharp edges of scratches to a
0.010A-0.014A and a shot size of S280.
maximum depth of 0.005 inch (0.13 mm)
and length of 0.375 inch (9.53 mm). (Alternate method) Flap peen the full
upper mating surface of the main rotor
(2). Remove sharp edges of nicks/scratches hub to specification MIL-R-81841 with
with 320-grit or finer sandpaper an intensity of 0.010A-0.014A and a
(C807). shot size of S280.
(3). Finish removal or sharp edges with (5). Apply chemical coating (C233) to repair
600-grit or finer abrasive cloth (C804). area (ref. CSP-SPM).
(4). Do an eddy current inspection of repair (6). Apply primer (C308) to repair area (ref.
area (ref. CSP-SPM). CSP-SPM).
(5). Apply alodine (C241) to repair area (ref. (7). Make a record in the Rotorcraft Log
CSP-SPM). Book of repair area.
Page 801
REMOVE CORROSION FROM

UPPER SURFACE OF UPPER HUB.
REMOVE SHARP EDGES OF SMALL SURFACE

NICKS AND SCRATCHES ON MACHINED EDGES
AND OUTER SURFACE OF WEB.
9G62046B
Figure 801. Main Rotor Hub Repair
1.50 INCH (38.1 MM)
2
1 VIEW LOOKING UP
(WEAR SHIM
REMOVED)
MATING SURFACE TYPICAL

(SHADED)
4
WEAR SHIM
VIEW LOOKING DOWN
9G62-061A
1. HUB PLATE 3. UPPER HUB

2. FLEXBEAM POCKET 4. LOWER HUB
Figure 802. Flexbeam Pockets, Hub Mating Surfaces, and Hub Plate
Page 802
C. Flexbeam Pockets and Hub Mating (2). Remove ion-vapor-deposited (IVD)

Surfaces Corrosion coating from both upper and lower
surfaces of hub plate (1).
(Ref. Figure 802)
(a). Use glass bead (ref. CSP-SPM) or
aluminum oxide grit blasting.
(Ref. CSPSPM) Remove corrosion to a maxi
CAUTION mum depth of 0.006 inch (0.15
Item Nomenclature
mm).
C804 Abrasive Cloth
(3). Remove corrosion (ref. CSP-SPM).
(4). Surface finish of hub plate after repair:
CAUTION
(a). Areas larger than 0.25 inch (6.4
Repairs to flexbeam pockets (2) are lim mm) and less than 0.50 inch (12.7
ited to 1.50 inch (38.1 mm) from out mm) from edge of part or hole,
board edge of pocket. surface to be 63 RMS or better.
Remove corrosion from flexbeam pockets (b). All other surfaces to be 125 RMS or
(2) to a maximum depth of 0.010 inch better.
(0.25 mm).
Remove corrosion from upper hub (3) and (c). If necessary, polish to get specified
lower hub (4) mating surfaces to a maxi finish.
mum depth of 0.006 inch (0.15 mm). (5). Clean and/or vapor degrease hub plate
(ref. CSP-SPM).
(1). Remove corrosion (ref. CSP-SPM).
Pasa-Jell 101 (C428)
(2). Finish removal of corrosion, use
600-grit or finer abrasive cloth (C804).
(3). Apply alodine (C241) to repair area (ref.

CSP-SPM).
(6). Apply Pasa-Jell 101 (C428) to hub
D. Hub Plate Corrosion plate for 30 to 60 minutes (ref.
manufacturers instructions).
(Ref. Figure 802) (7). Immediately put hub plate fully into
demineralized water and remove
Consumable Materials solution. Dry in air.
(Ref. CSPSPM)
(8). Apply low-embrittlement or cadmium
Item Nomenclature
plate to a minimum thickness of
C428 PasaJell 101 0.00050 inch (0.0127 mm) (ref.
QQ-P-416, Type I or Type II).
(1). Apply protection to identification to (9). If necessary, apply part and serial
prevent damage. number with electrochemical etch.
Page 803
3.50 INCH (88.9 MM)

2.50 INCH (63.5 MM)
15.2 INCH (38.61 CM)
14.8 INCH (37.59 CM)
2.00 INCH (50.8 MM)

1 (4 PLACES)
1.00 INCH (25.4 MM)
2
SIDE VIEW
9G62-076B
Figure 803. Flexbeam Bumper Replacement
Page 804
2. Repairs for the FlexbeamBumper (5). Do Step (4). until cloth stays clean.
Assemblies
A. Flexbeam Bumper Repair
(Ref. Figure 803)
Consumable Materials (6). Mix sealing compound (C201), refer to

(Ref. CSPSPM) manufacturers instructions.
Item Nomenclature
C201 Sealing Compound NOTE:
C425 Solvent, Cleaning You must mix sealant in a clean non-
C426 Adhesive waxed container.
C705 Tape, Polyethylene Apply sealant before expiration of its pot
C802 Cloth, NonLint life.
C810 Abrasive Cloth (7). Apply a 0.010 to 0.020 inch (2.54 to
5.08 mm) thick layer of sealing com
pound (C201) to the two mating
CAUTION surfaces. Do not use a metal tool.
Do not touch the flexbeam with metal or (8). Align bumper (1) with its installed
power tools when you do this procedure. position on flexbeam (2) and install
Do not bend flexbeam more than 10 de bumper. Do not move bumper after
grees during bumper removal or installa installation.
tion.
(9). Make sure sealing compound (C201)
(1). Remove tape and remove bumper (1). comes out all around bumper (1).
Be careful when you remove (10). Use a clamp or weight to apply pres
CAUTION adhesive. Do not damage glass sure until sealing compound cures.
fibers.
(11). Apply a thin layer of sealing compound
(2). Remove remaining adhesive with your (C201) to edge of bumper. Fully cure
hand. You can use a plastic or wood sealant.
scraper.
Adhesive (C426)
(3). Lightly rub surface with abrasive cloth
(C810) until surface primer not glossy.
(12). Apply a thin layer of adhesive (C426) to
bumper where tape will be installed.
Cure adhesive for 24 hours.
NOTE: (13). Wind two or three strips of polyethylene

tape (C705) around bumper (1) and
Mating surfaces of bumper and flexbeam
flexbeam (2).
must be clean and dry.
Dry surface while solvent is still wet. (a). Start and end tape on vertical sides
of bumper.
(4). Clean mating surfaces of bumper (1)
and flexbeam (2) with a non-lint cloth (b). Apply tape with a minimum tension
(C802) moist with cleaning solvent to keep deformation of bumper to a
(C425). minimum.
Page 805
3 2.00 INCH (50.8 MM)

1.00 INCH (25.4 MM)
SHEAR WEB
FLEXBEAM BRIDGE
1
APEX
1. AREA BETWEEN FLEXBEAM APEX AND FLEXBEAM 3. AREA WHERE NICKS CAN BE REPAIRED
BRIDGE WHERE FISSURES CAN BE FILLED
2. AREA ALONG OR UNDER FLEXBEAM BRIDGE
WHERE FISSURES CAN BE FILLED
Figure 804. Flexbeam Fissure Fill and Nick Repair
B. Flexbeam Fissure Fill NOTE:

(Ref. Figure 804) A fissure is an opening in surface of epoxy
resin or sealant on flexbeam.
Consumable Materials Fissures that are in resin between flex
(Ref. CSPSPM) beam apex and flexbeam bridge can be
Item Nomenclature filled.
C216 Sealant, Fuel Resistant Fissures that are in resin or sealant along
C425 Solvent, Cleaning or under flexbeam bridge can be filled.
C504 Resin, Epoxy
C802 Cloth, NonLint
Page 806
Solvent, Cleaning (C425) C. Flexbeam Nick Repair

(Ref. Figure 804)
(Ref. CSPSPM)
NOTE: Surface of the flexbeam must be clean, Item Nomenclature
dry, and have no contamination. C425 Solvent, Cleaning
C504 Resin, Epoxy
(1). Clean surface of flexbeam in area of
fissure (1, 2). C802 Cloth, NonLint
C807 Sandpaper
NOTE: Wipe surface before solvent dries.
(1). Break sharp edges of nick with sandpa
(a). Wipe surface with a non-lint cloth per (C807).
(C802) moist with cleaning solvent
(C425). Solvent, Cleaning (C425)
(b). Repeat until no visible residue shows

on the cloth.
Resin, Epoxy (C504) (2). Clean surface of flexbeam in area of

nick (3).
NOTE: Surface of flexbeam must be clean, dry,
and have no contamination.
Sealant, Fuel Resistant (C216) (a). Wipe surface with a non-lint cloth
(C802) moist with cleaning solvent
(C425).
NOTE: Wipe surface before solvent dries.
Resin, Epoxy (C504)
(2). Mix epoxy resin (C504) or sealant
(C216) (ref. manufacturers instruc
tions).
NOTE: You must mix epoxy resin or sealant in NOTE: You must mix epoxy resin in a clean
a clean wax free container. Apply epoxy res wax free container. Apply epoxy resin before
in or sealant before expiration of material expiration of material pot life.
pot life.
(3). Mix epoxy resin (C504) (Ref. manufac
(3). Apply a thin coat of epoxy resin (C504) turers instructions).
or sealant (C216) to seal fissure (1, 2). (4). Apply a thin coat of epoxy resin (C504)
to seal nick (3).
(4). Cure epoxy resin (C504) or sealant
(C216) (ref. manufacturers instruc (5). Cure epoxy resin (C504) (ref. manufac
tions). turers instructions).
Page 807
4 (5 PL)
10
6 (5 PL)
2
7 (5 PL) 8 (15 PL) 9 (15 PL)

UPPER AND LOWER
5 (5 PL)
REF. TABLE 801 FOR PARTS BREAKDOWN

9G62052A
Figure 805. Main Rotor Hub Configuration Change

3. Modification (2). Remove and disassemble upper hub (1),
lower hub (2) and hub plate (3) (ref.
A. Main Rotor Hub Configuration Change Main Rotor Hub Assembly).
(Ref. Table 801 and Figure 805) (3). Discard all parts and hardware that are
NOTE: unserviceable.
Table 801 shows the hub components nec (4). Assemble hub with components shown
essary to change early configuration hub in Table 801 (ref. Main Rotor Hub
assemblies to a more current configura Assembly).
tion.
(5). Permanently identify as 900R5101117
All early configuration hub assemblies
on identification plate (10).
can be changed to the 900R5101117 confi
guration. (6). Install identification plate on hub (ref.
This change is not mandatory. Identification Plate Installation).
(1). Remove main rotor hub assembly (ref. (7). Install main rotor hub assembly (ref.
Main Rotor Hub Assembly). Main Rotor Hub Assembly).
Page 808
Table 801. Main Rotor Hub Configuration Change

Item Qty Part Name Parts to be Removed Parts to be Installed
1. 1 Upper Hub Assembly 900R2101006xxx 900R2101006105 (serialized part)
2. 1 Lower Hub Assembly 900R2101008xxx 900R2101008107 (serialized part)
3. 1 Hub Plate 900R2101018xxx 900R2101018105 (serialized part)
4. 5 Flexbeam Bolt 900R2100011101 900R2100011103
5. 5 Lead Leg Wear Shim 900R2101003101 900R2101003103
6. 5 Lag Leg Wear Shim 900R2101015101 (if installed) 900R2101015103
7. 10 Slide Bushing 900R2101128101 (new part)
8. 15 Nut, Hex HS4447624C HS54896C
9. 15 Bolt, Head Tension HS5482642, 46 or Alternate HS5482650
10. 1 Identification (ID) Plate (old ID plate) HS47263
Page 809
Page 810
Section
623000
Swashplate and
Mixer
SWASHPLATE AND MIXER

1. Pitch Link Assembly (2). Remove the cotter pin (1), nut (2),
washer (3), bushing (5), washer (4) and
(Ref. Figure 401) bolt (6).
(3). Remove cotter pin (1), nut (2), washer
Consumable Materials (3) bushing (7), washer (4), and bolt (9).
(Ref. CSPSPM)
(4). Remove pitch link (11) with elastomer
Item Nomenclature
ring (12) from swashplate (8).
C702 Lockwire
B. Pitch Link Assembly Installation
NOTE:
A. Pitch Link Assembly Removal
This task is typical for pitch link assem
NOTE: bly installation.
Make sure the nominal length for a new
This task is typical for the pitch link as
pitch link is 16.60 inches (42.16 cm).
sembly removal.
Install the pitch link with end marked RH
Make sure the pitch link assemblies are in swashplate.
color coded to the pitchcase to minimize
effect on track and balance. Install the elastomer ring on pitch link
bearing before insertion into swashplate.
(1). Reduce the preload on upper controls (1). Install the bolt, washer, bushing, washer
from the main rotor flexbeams. and nut through the swashplate and
pitch link.
(a). Apply electrical power (Ref. Section
96-00-00). (a). Torque the nut (2) and install a new
cotter pin.
Moving Flight Controls (2). Install the bolt, washer, bushing
washer, and nut through pitchcase lug
and pitch link.
(a). Torque the nut (2) and install a new
cotter pin.
NOTE: Hydraulic power is not necessary.
(3). Torque the two pitch link nuts (13) to
(b). Release the collective friction 900 inch-lbs (101.7 Nm).
(Ref. Section 67-10-00). (4). Safety the pitch link nuts with
lockwire (C702).
(c). Lift the collective stick to approxi
mately 20% collective position, refer to (5). Do the main rotor track and balance
the indication on the IIDS. (Ref. Section 18-00-00).
Page 401
62-30-00 Revision 7
(5). Remove the scissors drive link assem

bly (20).
B. Scissors Drive Link Assembly
Installation
2
NOTE: Make sure there is 0.002-0.006 inch
10 1 (0.050-0.152 mm) of play between the drive
3 link assembly and rotor drive ring before
5 you torque the nuts (8).
6
13 (1). (Typical two places) Install the shims (6),
12
sleeves (10), washers (9 and 11), bolts
4 (12), and nuts (8) through upper drive
11 link assembly (5) and main rotor drive
ring.
13
9 (a). Torque the nuts (8) and install new
4 cotter pins (7).
(2). Install the washer (1) and nut (3) on
7 the lower drive link assembly (4).
8 3 (a). Torque the nut (3) and install a new
cotter pin (2).
2 1
9G62-070A 3. Scissors Lower Drive Link
1. COTTER PIN
2. NUT (Ref. Figure 402)
3. WASHER
4. WASHER
A. Scissors Lower Drive Link Removal
5. BUSHING (1). Remove and discard cotter pin (2).
6. BOLT
7. BUSHING (2). Remove the nut (3) and washer (1) from
8. SWASHPLATE
9. BOLT
the lower drive link assembly (4).
10. PITCHCASE LUG (3). Remove and discard cotter pin (13).
11. PITCH LINK
12. ELASTOMER RING (4). Remove the nut (14), washers (15 and
13. PITCH LINK NUTS
18) and bolt (19).
Figure 401. Pitch Link Assembly
(5). Support the upper drive link
assembly (5)
2. Scissors Drive Link Assembly
(6). Remove the pivot sleeve (16), laminated
(Ref. Figure 402) washers (17), and lower drive link
assembly (4).
A. Scissors Drive Link Assembly Removal
B. Scissors Lower Drive Link Installation
(1). Remove and discard cotter pin (2). Laminated washers must ride
CAUTION over sleeve and must not be off
(2). Remove the nut (3) and washer (1) from
set (trapped) during installation and torqu
the lower drive link assembly (4).
ing. Check to confirm laminated washers are
(3). (Typical two places) Remove and around sleeve of scissors drive link assembly.
discard cotter pin (7). NOTE: Bolt (19) head must be installed in the
direction of rotation of the main rotor system.
(4). (Typical two places) Remove the nut (8),
washer (9), shims (6), sleeve (10), (1). Assemble the lower link (4) to upper
washer (11), and bolt (12) from upper link (5) with laminated washers (17)
drive link assembly (5). and pivot sleeves (16).
Page 402
NOTE: Laminated washers (17) to be equal and 18), and nut (14). Torque the nut
within 0.002 inch (0.050 mm) of each other 30-40 inch pounds (3.39-4.52 Nm)
after adjustment for axial play. and install a new cotter pin (13).
(2). Adjust thickness of laminated washers (4). Install the washer (1) and nut (3) on
(17) to allow axial play between upper the lower drive link assembly (4).
and lowers scissors of 0.001-0.003 inch (5). Torque nut (3) and install a new cotter
(0.025-0.076 mm). pin (2).
(3). Attach the lower and upper link (6). Perform swashplate drive link
assemblies with bolt (19), washers (15 inspection.
5 REF
9
8
DIRECTION OF
15 ROTATION
12 14 18
11
10
7 5
13 19
16 16
2 PLACES 6 12 REF 20 17
4
4 REF
VIEW ROTATED
1
3
2
9G62-071C

4. LOWER DRIVE LINK ASSEMBLY 14. NUT
5. UPPER DRIVE LINK ASSEMBLY 15. WASHER
6. SHIM 16. PIVOT SLEEVE
7. COTTER PIN 17. LAMINATED WASHER
8. NUT 18. WASHER
9. WASHER 19. BOLT
10. SLEEVE 20. SCISSORS DRIVE LINK ASSEMBLY
Figure 402. Scissors Drive Link Assembly
Page 403
4. Lateral AntiTorque Drive Link Assembly (4). Torque the nut and install a new cotter
pin.
(Ref. Figure 403)
A. Lateral AntiTorque Drive Link Assembly 5. Longitudinal Drive Link Assembly
Removal
(Ref. Figure 403)
A. Longitudinal Drive Link Assembly
(2). Remove the nut (3), washer (4), Removal
bushing (5), washer (6), and upper
bolt (7). (1). Remove and discard cotter pin (21).
(3). Remove and discard cotter pins (8 and (2). Remove the nut (22), washer (23),
14). bushing (24), washer (25), and upper
bolt (26).
(4). Remove the nuts (9 and 15), washers
(10 and 16), bushings (11 and 17), (3). Remove and discard cotter pin (27).
washers (12 and 18) and lower bolts (13
and 19). (4). Remove the nut (28), washer (29),
bushing (30), washer (31), and lower
(5). Remove torque link (20). bolt (32).
B. Lateral AntiTorque Drive Link Assembly
(5). Remove drive link (33).
Installation
(1). Install the torque link, lower bolts, B. Longitudinal Drive Link Assembly
washers, bushings, and nuts. Installation
(2). Torque the nuts and install new cotter (1). Install drive link, bolts, washers,
pins. bushings, and nuts.
(3). Install the upper bolt, washers, bush (2). Torque the nuts and install new cotter
ing, and nut. pins.
Page 404
Revision 7 62-30-00
24 23 22
21 7
26 25
1
6
4
33
2
20
32
31
10 8
11
30 12
13
9
15
34
29
28 14
17 16
27 19
35 18 9G62-074
1. SWASHPLATE 19. BOLT
2. COTTER PIN 20. LATERAL DRIVE LINK
4. WASHER 22. NUT
7. BOLT 25. WASHER
8. COTTER PIN
26. BOLT
9. NUT
27. COTTER PIN
10. WASHER
28. NUT
11. BUSHING
13. BOLT 30. BUSHING
15. NUT 32. BOLT
16. WASHER 33. LONGITUDINAL DRIVE LINK
17. BUSHING 34. LONGITUDINAL MIXER BELLCRANK ASSEMBLY
18. WASHER 35. LATERAL MIXER BELLCRANK ASSEMBLY
Figure 403. Lateral and Longitudinal Link Assembly
6. NonAdjustable Collective Drive Link (3). Release collective friction (Ref. Section
Assembly 67-10-00) and raise collective stick
slightly to unload flight controls.
(Ref. Figure 404)
(4). Disconnect upper end of lateral and
A. NonAdjustable Collective Drive Link longitudinal drive links to enable
Assembly Removal movement of swashplate.
(1). Remove forward access door assemblies (5). Remove and discard cotter pin (9).
L155 and R155 (Ref. Section
53-30-00). (6). Remove nut (8), washers (6 and 7) and
upper bolt (5).
(2). Remove forward swashplate fairing
assembly T155 (Ref. Section 53-30-00). (7). Remove and discard cotter pin (25).
Page 405
62-30-00 Revision 3
(8). Remove nut (24), washer (23) shims (5). Remove and discard cotter pin (15).
(10), bushing (22), washer (21) and
lower bolt (20). (6). Remove nut (16), washer (14), shims
(13), washer (12), and upper bolt (11).
(9). Raise swashplate to allow removal of
drive link (1). (7). Remove and discard cotter pin (27).
B. NonAdjustable Collective Drive Link
(8). Remove nut (28), washer (26), bushing
Assembly Installation
(19), washer (18), and lower bolt (17).
NOTE: Install peel shims to both sides of clevis
to obtain 0.002-0.006 inch (0.050-0.152 (9). Raise swashplate to allow removal of
mm) play prior to torque. drive link (2).
(1). Install drive link, lower bolt, washer, B. Adjustable Collective Drive Link
bushing, shims, washer, and nut. Assembly Installation
Torque nut and install new cotter pin.
NOTE:
(2). Install upper bolt, washers, and nut.
Torque nut and install new cotter pin. If installing new adjustable collective
drive link, ensure there is a nominal
(3). Connect lateral and longitudinal drive length of 3.750 inches (9.525 cm) from
links. center of bearing to center of clevis end. If
adjustment is required to allow installa
(4). Install forward swashplate fairing tion, cut safety wire, loosen both jamnuts
assembly T155 (Ref. Section 53-30-00). and rotate barrel. Torque jamnuts
(5). Install forward access door assemblies 660-780 in-lbs. (74.55 - 88.11 N.m) and
L155 and R155 (Ref. Section safety wire.
53-30-00). Install peel shims to both sides of clevis to
obtain 0.002-0.006 inch (0.050-0.152
7. Adjustable Collective Drive Link mm) play prior to torque.
Assembly
(Ref. Figure 404) (1). Install drive link, lower bolt, washers,
bushing, washer, and nut. Torque nut
A. Adjustable Collective Drive Link and install new cotter pin.
Assembly Removal
(2). Install upper bolt, washer, shims,
(1). Remove forward access door assemblies washer, and nut. Torque nut and install
L155 and R155 (Ref. Section new cotter pin.
53-30-00).
(3). Connect lateral and longitudinal drive
(2). Remove forward swashplate fairing
links.
assembly T155 (Ref. Section 53-30-00).
(3). Release collective friction (Ref. Section (4). Install forward swashplate fairing
67-10-00) and raise collective stick assemblies T155 (Ref. Section
slightly to unload flight controls. 53-30-00).
(4). Disconnect one end of lateral and (5). Install forward access door assemblies
longitudinal drive links to enable L155 and R155 (Ref. Section
movement of swashplate. 53-30-00).
Page 406
Revision 3 62-30-00
SHIM
CLEVIS 13
12 11
5
14 6
15
7
16 8
1
2
10
4 REF 9
26 27
SHIM INSTALLATION TYP
25 4
17
23 18
19
28
24 3
22
3 REF 21
20
9G62-073
1. NONADJUSTABLE COLLECTIVE DRIVE LINK 15. COTTER PIN

2. ADJUSTABLE COLLECTIVE DRIVE LINK 16. NUT
3. LATERAL MIXER BELLCRANK ASSEMBLY 17. BOLT
4. LONGITUDINAL MIXER BELLCRANK ASSEMBLY 18. WASHER
5. BOLT 19. BUSHING
6. WASHER 20. BOLT
8. NUT 22. BUSHING
10. SHIM 24. NUT
13. SHIM 27. COTTER PIN
14. WASHER 28. NUT
Figure 404. Nonadjustable and Adjustable Collective Link
Page 407
62-30-00 Revision 3
8. Mixer (2). Disconnect lower end of lateral anti-

torque drive link.
(Ref. Figure 405)
A. Mixer Removal (3). Remove and discard cotter pin (24).
(1). Disconnect upper end of lateral, (4). Remove nut (23), washer (22), lateral
longitudinal, and collective hydraulic pivot cap (21), bolt (17), retaining ring
actuators (Ref. Section 67-10-00). (19), lateral pivot support (18), and
(2). Remove lateral anti-torque drive link. lateral pivot thrust washer (20).
Remove lateral mixer bellcrank (4).
(3). Remove longitudinal drive link.
B. Lateral Mixer Bellcrank Installation
(4). Remove adjustable and non-adjustable
collective drive links.
(Ref. CSPSPM)
(6). Remove nut (9), washer (8), bushing Item Nomenclature
(7), washer (6), and left bolt (5). C308 Primer
(14),bushing (13), washer (12), and
right bolt (11). Remove mixer (1). (1). Install lateral mixer bellcrank.
B. Mixer Installation (2). Install lateral pivot thrust washer,

lateral pivot support, and retaining
(1). Install mixer, left bolt, washer, bushing,
ring.
washer, and nut. Torque nut and install
new cotter pin.
NOTE: If you use waterborne primer, do not
(2). Install right bolt, washers, bushings, thin with water. Use acetone (C436).
and nut. Torque nut and install new
cotter pin. Primer (C308)
(3). Install adjustable and non-adjustable
collective drive links.
(4). Install longitudinal drive link.
(5). Install lateral anti-torque drive link. (3). Install bolt, install wet with primer
(C308).
(6). Connect upper end of lateral, longitudi
nal, and collective hydraulic actuators
(Ref. Section 67-10-00). (4). Install lateral pivot cap, washer, and
nut. Torque nut and install new cotter
9. Lateral Mixer Bellcrank pin.
(Ref. Figure 405) (5). Connect lower end of lateral anti-

torque drive link.
A. Lateral Mixer Bellcrank Removal
(1). Disconnect upper end of lateral hydrau (6). Connect upper end of lateral hydraulic
lic actuator (Ref. Section 67-10-00). actuator (Ref. Section 67-10-00).
Page 408
10. Longitudinal Mixer Bellcrank (5). Connect lower end of longitudinal drive
link.
(Ref. Figure 405)
(6). Connect upper end of longitudinal
A. Longitudinal Mixer Bellcrank Removal hydraulic actuator (Ref. Section
67-10-00).
(1). Disconnect upper end of longitudinal
hydraulic actuator (Ref. Section 11. Collective Mixer Bellcrank
67-10-00).
(Ref. Figure 405)
(2). Disconnect lower end of longitudinal
drive link. A. Collective Mixer Bellcrank Removal
(3). Remove and discard cotter pin (32). (1). Disconnect upper end of collective
hydraulic actuator (Ref. Section
(4). Remove nut (31), washer (30), longitu 67-10-00).
dinal pivot cap (29), bolt (25), retaining
ring (27), longitudinal pivot support (2). Remove lateral mixer bellcrank.
(26), and longitudinal pivot thrust (3). Remove longitudinal mixer bellcrank.
washer (28). Remove longitudinal mixer
bellcrank (3). (4). Disconnect lower ends of non-adjust
able and adjustable collective drive
B. Longitudinal Mixer Bellcrank Installation links.
(Ref. CSPSPM) (6). Remove nut (9), washer (8), bushing
Item Nomenclature (7), washer (6), and left bolt (5).
C308 Primer
(14), bushing (13), washer (12), and
(1). Install longitudinal mixer bellcrank. right bolt (11). Remove collective mixer
bellcrank (2).
(2). Install longitudinal pivot thrust
washer, longitudinal pivot support, and B. Collective Mixer Bellcrank Installation
retaining ring. (1). Install collective mixer bellcrank, left
NOTE: If you use waterborne primer, do not bolt, washer, bushing, washer, and nut.
thin with water. Use acetone (C436). Torque nut and install new cotter pin.
(2). Install right bolt, washers, bushings
Primer (C308)
and nut. Torque nut and install new
cotter pin.
(3). Connect lower ends of non-adjustable
and adjustable collective drive links.
(3). Install bolt, install wet with primer (4). Install longitudinal mixer bellcrank.
(C308).
(5). Install lateral mixer bellcrank.
(4). Install longitudinal pivot cap, washer,
and nut. Torque nut and install new (6). Connect upper end of collective hydrau
cotter pin. lic actuator (Ref. Section 67-10-00).
Page 409
29
30
31
25
26
27 23
28 22 21
24
3 32
13
12
11
5
6 20 19
18
17
2
4
16
10
15
14
10
33
34
9G62009C
1. MIXER 18. LATERAL PIVOT SUPPORT

2. COLLECTIVE MIXER BELLCRANK 19. RETAINING RING
3. LONGITUDINAL MIXER BELLCRANK 20. LATERAL PIVOT THRUST WASHER
4. LATERAL MIXER BELLCRANK 21. LATERAL PIVOT CAP
5. BOLT 22. WASHER
6. WASHER 23. NUT
7. BUSHING 24. COTTER PIN
8. WASHER 25. BOLT
9. NUT 26. LONGITUDINAL PIVOT SUPPORT
10. COTTER PIN 27. RETAINING RING
11. BOLT 28. LONGITUDINAL PIVOT THRUST WASHER
12. WASHER 29. LONGITUDINAL PIVOT CAP
14. BUSHING 31. NUT
16. NUT 33. RIGHT MIXER SUPPORT
17. BOLT 34. LEFT MIXER SUPPORT
Figure 405. Mixer
Page 410
12. Swashplate Azimuth Sensor (4). Torque nuts. Safety with lockwire
(C702).
(Ref. Figure 406)
(Ref. CSPSPM)
Item Nomenclature
C702 Lockwire
A. Swashplate Azimuth Sensor Removal

VIEW LOOKING UP
(1). Disconnect electrical connector P430
(5).
(2). Cut and discard lockwire from azimuth 1
sensor jam nuts (2) and (3).
5
(3). Remove azimuth sensor (1).

ROTATING
B. Swashplate Azimuth Sensor Installation SWASHPLATE
NOTE: If this is the first installation of an

MHS5284 azimuth sensor, you must change

0.025 - 0.035 in
the electrical connector to a (0.635 - 0.889 mm) GAP

MS3456W10SL-4S, electrical connector

backshell to a MHS5842WR1002L, and get 4
two NAS1423C10 nuts. Discard nut that
comes on azimuth sensor.

(1). On rotating swashplate, turn setscrew
in until flush. 3 STATIONARY
SWASHPLATE
(2). Measure gap between rotating and
stationary swashplates. Turn setscrew 1 2
out half the distance between swash
plates minus 0.025 in. (0.64 mm). 9G62-072
1. AZIMUTH SENSOR
(3). Install azimuth sensor into stationary 2. NUT
swashplate until distance between 3. NUT
azimuth sensor and setscrew is 4. SETSCREW
5. CONNECTOR (P430)
0.025-0.035 in. (0.635-0.889 mm).
Tighten nut. Figure 406. Swashplate Azimuth Sensor
Page 411
13. Swashplate Assembly 14. Swashplate Bearing Retainer Rings and

Labyrinth Seals
A. Swashplate Assembly Removal
A. Retainer Rings and Seals Removal
(1). Remove main rotor hub (Ref. Section
(Ref. Figure 407)
62-20-00).
(1). Remove and discard lockwire from bolts
(2). Remove pitch link assemblies. (1).
(3). Remove scissors drive link assembly. (2). Remove bolts (1) and washers (3) from
top of swashplate (2).
(4). Disconnect lateral anti-torque drive
link. NOTE: If one piece retaining rings are
installed, it is necessary to remove rotor
(5). Disconnect longitudinal drive link head assembly (Ref. Section 62-20-00).
assembly.
(3). Remove labyrinth seal rings (4 and 5)
and inner and outer bearing retainer
(6). Disconnect non-adjustable and adjust
rings (8 and 9).
able collective drive link assemblies.
8
(7). Disconnect azimuth sensor connector 1
4
P431.
3
(8). Lift swashplate up and from static

mast. 6
NOTE: If replacing swashplate remove azi 1

9
muth sensor (1).

3
B. Swashplate Assembly Installation

5
(1). Install swashplate (1).
NOTE: If replacing swashplate install azimuth 7

sensor (1). 2
(2). Install connector P431.
(3). Connect non-adjustable and adjustable

collective drive link assemblies.
(4). Connect longitudinal drive link assem

9G62030A
bly. 1. BOLT
2. SWASHPLATE
(5). Connect lateral anti-torque drive link 3. WASHER
assembly. 4. NONROTATING SWASHPLATE LABYRINTH SEAL
RING
5. ROTATING SWASHPLATE LABYRINTH SEAL RING
(6). Install main rotor hub (Ref. Section 6. INNER BEARING RETAINER RING EARLY CONFIG
62-20-00). 7. OUTER BEARING RETAINER RING EARLY CONFIG
8. INNER BEARING RETAINER RING CURRENT CONFIG
9. OUTER BEARING RETAINER RING CURRENT CONFIG
(7). Install scissors drive link assembly.
Figure 407. Retainer Rings and Seals
(8). Install pitch link assemblies. Removal
Page 412
Revision 3 62-30-00
B. EARLY CONFIG Retainer Rings and (a). Mask the angular and spherical
Seals Installation (One Piece Retainer swashplate bearings and plug bolt
Ring) holes.
(Ref. Figure 408) No scratches or damage to

CAUTION swashplate assembly allowed.
Consumable Materials Paint Stripper (C313)

(Ref. CSPSPM)
Item Nomenclature
C702 Lockwire
C313 Paint Stripper
(b). Carefully remove paint from upper
surface of swashplate with paint
C308 Primer stripper (C313) and a hard plastic
scraper.
NOTE: (c). Carefully remove paint stripper

residue.
Measurements must be performed with
the swashplate temperature between 55 (d). Stop chemical action of stripper with
F-95 F (12.9 C-35.3 C). demineralized water.
Install three bolts with large area wash
ers into the rotating swashplate to pre Alcohol, Isopropyl (C419)
vent the rotating swashplate from slip
ping down during measurements.
Install bolts approximately 120 apart,
and move bolts to measure near all bolt
holes. (e). Clean area with isopropyl alcohol
(C419).
All measurements must be greater than
0.0000 in. (0.000 mm). Any single mea Primer (C308)
surement below this dimension requires
performing paint removal portion of this
procedure.
(1). Using a depth micrometer, measure the

height dimension between the upper (f). Apply a thin film of primer (C308)
surface of the inner bearing race and and allow to dry.
the top surface of the non-rotating
swashplate at ten locations adjacent to (g). Remove masking and plugs.
bolt holes. Record average dimension.
(h). Repeat steps (1). through (3).
(2). Repeat step (1). between outer bearing
NOTE: If either average dimension is less than
race and top of rotating swashplate.
0.0055 in. (0.140 mm) after second mea
surement, replace swashplate assembly.
(3). If both average dimensions (inner and
outer) are 0.0055 in. (0.140 mm) or (5). Install labyrinth seal rings and bearing
greater, proceed to step (5). retainer rings with bolts and washers.
Torque bolts 70-90 in-lbs (7.91-10.17
(4). If either average dimension is less than Nwm).
0.0055 in. (0.140 mm), perform the
following: (6). Safety bolts using lockwire (C702).
Page 413
BOLT WITH LARGE MEASURING

AREA WASHER (3PL) POINT (10 PL)
MEASURING BEARING OUTER RACE BEARING INNER RACE

POINT (10 PL)
BEARING BEARING
HEIGHT HEIGHT
DIMENSION DIMENSION
SPHERICAL SLIDER
BEARING
OUTER RACE
NON-ROTATING
ROTATING SWASHPLATE
SWASHPLATE
9G62045A
Figure 408. EARLY CONFIG Swashplate Bearing Preload Measurement

(One Piece Retainer Rings Installation)
C. CURRENT CONFIG Retainer Rings and (3). Install two piece inner and outer retainer
Seals Installation (Two Piece Retainer rings onto swashplate (recessed surface
Ring) pointed down) with gap between ring
halves approximately equal.
(Ref. Figure 409)
(Ref. CSPSPM)
Item Nomenclature
C702 Lockwire
(4). Apply sealing compound (C203) to fill
gap between retainer ring halves.
(1). Inspect the upper surface of swashplate
bearing inner and outer race. Bearing (5). Install inner and outer labyrinth seal
must be flush with or higher than the rings with bolts and washers. Torque
top surface of the non-rotating and bolts 70-90 inch-pounds (7.91-10.17
rotating swashplate. Nm).
(2). If the swashplate fails inspection, contact
MDHS Field Service for disposition. (6). Safety bolts using lockwire (C702).
Page 414
Revision 3 62-30-00
RETAINING RING,
INNER (NOTE)
BEARING, ANNULAR CONTACT NOTE: UP MARKING ON TOP OF RINGS
ROTATING RETAINING RING,
SWASHPLATE OUTER (NOTE)
SPHERICAL SLIDER BEARING
RETAINER RING, INNER

NON-ROTATING GAP APPROXIMATELY EQUAL
SWASHPLATE
RETAINING RING, OUTER

GAP APPROXIMATELY EQUAL
RETAINER INSTALLATION
TOP VIEW
9G62044A
Figure 409. CURRENT CONFIG Swashplate Retainer Rings Installation

(Two Piece Retainers)
15. NonRotating Swashplate A. NonRotating Swashplate Removal
(Ref. Figure 410) (1). Remove main rotor swashplate assembly.
Consumable Materials (2). Remove swashplate bearing retainer

(Ref. CSPSPM) rings and labyrinth seals.
Item Nomenclature
C220 Compound, AntiSeize (3). Place angular contact ball bearing
C702 Lockwire support tool (T506) (1) on base of press.
Special Tools (4). Place swashplate assembly (2) on top of

(Ref. CSPSPM) tool, ensuring the three tool dowels
Item Nomenclature pass through notches at bottom of
non-rotating swashplate and contact
T506 Support Tool, Angular Contact Ball Bearing inner race of swashplate bearing.
T505 Press Plate, Swashplate
T507 Support Tool, NonRotating Swashplate (5). Thread three NAS6604-60 bolts (3)
into top of non-rotating swashplate (8).
Page 415
62-30-00 Revision 3
(6). Place swashplate press plate (T505) (5) (4). Partially install outer labyrinth seal
on bolt heads. Ensure swashplate and bearing retainer with all but three
assembly and tooling are centered bolts and washers.
beneath piston of press. Press non-ro
tating swashplate assembly from (5). Thread three NAS6604-60 bolts into
rotating swashplate. rotating swashplate assembly.
B. NonRotating Swashplate Installation (6). Center rotating swashplate assembly
over non-rotating swashplate.
(1). Place non-rotating swashplate support
tool (T507) (6) on base of press.
(7). Place swashplate press plate (T505) on
(2). Support non-rotating swashplate on bolt heads. Ensure swashplate assem
support tool. bly and tooling are centered beneath
piston of press. Press rotating swash
Compound, Anti-Seize (C220) plate onto non-rotating swashplate
assembly.
(8). Remove three NAS6604-60 bolts from

rotating swashplate assembly.
(3). Apply a thin coat of anti-seize com
pound (C220) to outside diameter of (9). Install swashplate bearing retainer
non-rotating swashplate. rings and labyrinth seals.
5
5
3 (3 PL)
3 (3 PL)
8
4 7 4
1
6
SWASHPLATE REMOVAL SWASHPLATE INSTALLATION 9G62-069

1. ANGULAR CONTACT BALL BEARING SUPPORT TOOL 5. SWASHPLATE PRESS PLATE (T505)
(T506) 6. NONROTATING SWASHPLATE SUPPORT TOOL
2. SWASHPLATE ASSEMBLY (T507)
3. NAS660460 BOLT 7. ANGULAR CONTACT BALL BEARING
4. NONROTATING SWASHPLATE ASSEMBLY 8. ROTATING SWASHPLATE ASSEMBLY
Figure 410. NonRotating Swashplate Installation
Page 416
16. Swashplate Spherical Slider Bearing (6). Place swashplate press plate (T505) (7)
on bolt heads. Ensure swashplate
(Ref. Figure 411) assembly and tooling are centered
beneath piston of press. Press swash
Consumable Materials plate assembly from spherical slider
(Ref. CSPSPM) bearing.
Item Nomenclature
B. Swashplate Spherical Slider Bearing
C220 Compound, AntiSeize Installation
C702 Lockwire
(1). Place non-rotating swashplate support
tool (T507) (1) on base of bearing press.
Special Tools
(Ref. CSPSPM) (2). Support swashplate assembly on
Item Nomenclature non-rotating swashplate support tool
T504 Support Tool, Spherical Slider Bearing (T507).
T505 Press Plate, Swashplate Compound, Anti-Seize (C220)
T507 Support Tool, NonRotating Swashplate
A. Swashplate Spherical Slider Bearing

Removal
(3). Apply a thin coat of anti-seize com
(1). Remove swashplate bearing retainer pound (C220) to outer diameter of
rings and labyrinth seals. spherical slider bearing.
(2). Remove nuts (12), washers (11), bolts (4). Place spherical slider bearing in center
(10), and brackets (8 and 9). of non-rotating swashplate.
(3). Thread three NAS6604-60 bolts (6) (5). Place spherical slider bearing support
into non-rotating swashplate. tool (T504) on spherical slider bearing
and press bearing into non-rotating
(4). Place spherical slider bearing support swashplate assembly.
tool (T504) (5) on base of press.
(6). Install brackets with bolts, washers,
(5). Place swashplate assembly (2) on top of and nuts. Torque nuts to 50-70 in-lb
tool, ensuring the three tool dowels (5.65-7.91 Nwm).
pass through notches at bottom of
non-rotating swashplate and contact (7). Install swashplate bearing retainer
outer race of spherical bearing (3). rings and labyrinth seals.
Page 417
12 (4 PL) 8
11 (4 PL) 3
7 10 (4 PL)
5
6 (3 PL)
3
3
4 2
ROTATED 180 DEGREES
2
5 1
BEARING INSTALLATION
BEARING REMOVAL
9G62-068
1. NONROTATING SWASHPLATE SUPPORT TOOL 7. SWASHPLATE PRESS PLATE (T505)

(T507) 8. BRACKET
2. SWASHPLATE ASSEMBLY 9. BRACKET
3. SPHERICAL SLIDER BEARING 10. BOLT
4. NONROTATING SWASHPLATE 11. WASHER
5. SPHERICAL SLIDER BEARING SUPPORT TOOL (T504) 12. NUT
6. NAS660460 BOLT
Figure 411. Swashplate Spherical Slider Bearing
C. Swashplate Angular Contact Ball Bearing D. Swashplate Ball Bearing Removal

(1). Remove non-rotating swashplate.
(Ref. Figure 412)
(2). Thread three NAS6604-60 bolts (2)
into rotating swashplate (1).
(Ref. CSPSPM) (3). Place a wooden board on base of press.
Item Nomenclature
(4). Place swashplate upside down on
C220 Compound, AntiSeize wooden board.
(5). Place angular contact ball bearing
Special Tools
support tool (T506) (3) on top of bearing
(Ref. CSPSPM)
(4) and press bearing from swashplate.
Item Nomenclature
T505 Press Plate, Swashplate E. Swashplate Ball Bearing Installation
T506 Support Tool, Angular Contact Ball Bearing (1). Heat rotating swashplate to approxi
mately 1505 F (65.65 C).
Page 418
(2). Place a wooden board on base of press. (4). Place swashplate on wooden board.
(5). Place bearing on top of swashplate.
(6). Place swashplate press plate (T505) (5)

on top of bearing and carefully press
bearing into swashplate.
(3). Apply a coat of anti-seize compound
(C220) to inside diameter of rotating
swashplate. (7). Install non-rotating swashplate.
3
5
1
4
2 (3 PL)
BEARING INSTALLATION 9G62067

BEARING REMOVAL A
1. ROTATING SWASHPLATE 4. ANGULAR CONTACT BALL BEARING
2. NAS660460 BOLT 5. SWASHPLATE PRESS PLATE (T505)
3. ANGULAR CONTACT BALL BEARING SUPPORT TOOL
(T506)
Figure 412. Swashplate Ball Bearing
Page 419
Page 420
SWASHPLATE AND MIXER

INSPECTION/TEST
1. Swashplate Assembly (7). With pitch links and swashplate drive
link disconnected, inspect for smooth
(Ref. Figure 601) ness of rotation. No ratcheting, noise, or
A. Swashplate Assembly Inspection binding permitted.
(8). Inspect bearing lower grease seal for
(1). Inspect for gouges, dents and scratches.
leakage. Minor grease leakage allowed
No damage permitted.
if bearing operates smoothly.
(2). Inspect for corrosion. None permitted.
(9). Inspect labyrinth seals for gouges,
(3). Inspect for wear between clevis and dents and scratches. No damage
pitch link rod ends. None permitted. permitted.
(4). Inspect spherical slider bearing (3) for (10). Inspect the drive link attach spherical
maximum play in non-rotating swash bearing (11) for a maximum play of
plate (1) of 0.011 inch (0.279 mm) 0.008 inch (0.203 mm) radial and
radial and 0.035 inch (0.889 mm) 0.040 inch (1.016 mm) axial.
axial. B. Swashplate Assembly Upper Bearing
(5). Inspect spherical slider bearing (3) for a Inspection
maximum radial play on static mast of (1). Remove bolts (8), washers (9), retainer
0.020 inch (0.508 mm). rings (4 and 5), and labyrinth seals (6
(6). Inspect spherical bearings where the and 7).
collective, lateral and longitudinal links (2). Inspect for corrosion. None permitted.
attach (12, 13, and 14) to non-rotating
swashplate (1) . Check for a maximum (3). Inspect for grease leakage. Minor
play of 0.008 inch (0.203 mm) radial grease leakage allowed if bearing
and 0.040 inch (1.016 mm) axial. operates smoothly.
Page 601
12 (2 PL)
A
13 11
11 2
4 13
7 REF 6 10
8 (20 PL) 3
9 (20 PL)
6 REF
7
5
14
2
A
Section A-A 9G62029A
1. NONROTATING SWASHPLATE ASSEMBLY 8. BOLT
2. ROTATING SWASHPLATE ASSEMBLY 9. WASHER
3. SELFALIGNING SPHERICAL/SLIDER BEARING 10. ANGULAR CONTACT BALL BEARING
4. BEARING RETAINER RING, OUTER 11. SPHERICAL BEARING, DRIVE LINK ATTACH
5. BEARING RETAINER RING, INNER 12. SPHERICAL BEARING, COLLECTIVE LINK ATTACH
6. LABYRINTH SEAL RING, ROTATING 13. SPHERICAL BEARING, LATERAL ATTACH
7. LABYRINTH SEAL RING, NONROTATING 14. SPHERICAL BEARING, LONGITUDINAL ATTACH
Figure 601. Swashplate Assembly
Page 602
C. Swashplate Drive Link Inspection (d). Prevent the rotor from turning, use
rotor brake (if installed).
(Ref. Figure 602)
(1). Inspect to determine the rotational play (e). Manually rotate swashplate forward
between the rotating swashplate and and backward without moving the
the lower drive link.
main rotor. Maximum allowable play
(a). Ensure collective control is in down of 0.140 inch (3.556 mm).
position and cyclic control is in
neutral position .
(f). If allowable play is exceeded, repair
(b). Ensure laminated washers (3) are or replace drive scissors assembly (ref
around outside diameter of sleeve (2) Scissors Drive Link Assembly
and not offset (trapped). If washers Repair).
are offset, replace the lower drive
link and attaching hardware.
(2). Inspect for gouges, dents and scratches.
(c). Attach a dial indicator so the plunger Repair or replace drive scissors assem
is compressed against the head of one bly (ref Scissors Drive Link Assembly
of the lower pitch link attach bolts. Repair).
2 4
5 (2 PL)
3 6
7
1
VIEW ROTATED 9G62043A
1. LOWER DRIVE LINK 5. WASHER
2. DRIVE LINK PIVOT SLEEVE 6. NUT
3. LAMINATED WASHER 7. COTTER PIN
4. BOLT
Figure 602. Swashplate Drive Link Assembly
Page 603
2. Mixer Assembly Inspection (2). Inspect bearings for a maximum play of

0.008 inch (0.203 mm) radial and
0.040 inch (1.016 mm) axial.
(Ref. Figure 603)
(3). Inspect links for gouges and scratches.
(1). Visually inspect the aft end of the No damage permitted.
lateral mixer bellcrank (1) and lateral (4). Inspect for corrosion. None permitted.
anti-torque drive link (2). Use a bright
light and 5X magnification. No cracks (5). Inspect bellcranks for gouges, dents
permitted. and scratches. No damage permitted.
2
1

INSPECTION AREA
FOR CRACKS
VIEW ROTATED
9g62-079
1. LATERAL MIXER BELLCRANK 2. LATERAL ANTITORQUE DRIVE LINK
Figure 603. Lateral Mixer Bellcrank And Lateral Antitorque Drive Link
Page 604
3. Pitch Link Inspection (Area 4) (3). LATER CONFIG - Examine bearing

for a maximum play of 0.005 in. (0.127
(Ref. Figure 604) mm) radial and 0.025 in. (0.635 mm)
(1). Examine pitch link for gouges and axial.
scratches. No damage permitted.
(4). Examine bearing for corrosion, contam
(2). EARLY CONFIG - Examine bearing ination, or binding. None permitted.
for a maximum play of 0.008 in. (0.203
mm) radial and 0.040 in. (1.016 mm) (5). Examine for wear with swashplate
axial. clevis. None permitted.
CERAMIC
MATERIAL
LATER CONFIG
EARLY CONFIG
9g62-078A
Figure 604. Pitch Links
Page 605
Page 606
SWASHPLATE AND MIXER COMPONENTS

REPAIR
1. Pitch Link Bearing (3). Examine pitch link housing and bore
for cracks, use a 10 X magnifying glass.
No cracks permitted.
A. Pitch Link Bearing Removal (4). Examine bore of pitch link for scratches
through anodize coating, use a 10 X
magnifying glass. No scratches per
(Ref. Figure 801) mitted.
(5). Make a measurement of housing bore.
Maximum permitted dimension 0.9053
Consumable Materials in. (22.9946 mm).
(Ref. CSPSPM)
B. Pitch Link Bearing Installation
Item Nomenclature
C317 Primer, Epoxy CAUTION

C429 Solvent Cleaner Do not heat housing more than 350 F
(177 C).
Do not cool bearing less than -321 F
(-196 C).
NOTE: (1). Heat pitch link housing and if neces
sary, cool bearing.
This task is typical for the two pitch link
bearings. CAUTION
When bearings have been replaced more Do not use primer that contains chlori
than one time, you must do a careful in nated solvents.
spection of housing bore. Primer must not go into bearing.
Do not apply a force of more than 450 lbs.
(204 Kg).
When you remove bearings, do
CAUTION Primer, Epoxy (C317)
not damage housing bore. Use
tools of applicable size.
(1). Remove bearing, use applicable tools (2). Install bearing. Install bearing wet
and hydraulic press. with epoxy primer (C317). Use applica
ble tools and hydraulic press.
Solvent Cleaner (C429) (3). Make sure bearing stays flush to pitch
link housing.
(4). Let parts cool to ambient temperature.
NOTE: Make sure bearing can not be pushed
from housing with your fingers.
(5). Remove primer from bearing surfaces.
(2). Remove red dot, sealant and/or primer, (6). Apply primer (C308) to make a fillet
use solvent cleaner (C429) and a plastic between outer edge of bearing and
or wooden scraper. housing.
Page 801

STAKED FLANGE

PRESS TOOL
HOUSING
HOUSING

SUPPORT
0.9053 IN. (22.9946 mm)

MAXIMUM PERMITTED
DIMENSION

BEARING
REMOVAL 9G62058B
Figure 801. Pitch Link Bearing Removal and Bore Inspection
C. Pitch Link Bearing Staking

CAUTION
(Ref. Figure 802)
Do not apply a force of more than 15,000
lbs. (6,804 Kg).
Special Tools
(Ref. CSPSPM) Do not crack bearing.
Item Nomenclature
T2024 Staking Tool, TriRoller Install a safety shield
T2025 Staking Tool, Anvil WARNING around press.
NOTE: (1). Apply force to equally stake bearing all

around until it contacts housing
Lip of machined groove in bearing outer chamfers, use tri-roller staking tool
race is rolled outboard on housing bore. (T2024) or anvil staking tool (T2025).
During roller staking, rollers must be suf
ficiently lubricated and must not stick or NOTE: Staking of bearing a second time is per
slide. mitted, if there are no cracks or other dam
Set up tool and housing so tool is aligned age.
with housing bore.
Make sure housing will not move during (2). Examine housing and outer race for
staking. cracks. None permitted.
Page 802
STAKING TOOL

BEARING OUTER RACE
ROLLED OUTBOARD

ON HOUSING

HOUSING

STAKING TOOL

HOUSING

PILOT

BEARING OUTER RACE
PLATEN
ANNULAR PRESS LIP STAKING

RETAINER SWAGING

ROLLER
BEARING MUST BE 0.010 IN. (0.254 mm) 0.002 IN (0.051 mm)

MAXIMUM ABOVE OR BELOW MAXIMUM
SURFACE OF HOUSING

PILOT

HOUSING BEARING

NECESSARY DIMENSIONS BEFORE STAKING

ARBOR
PLATEN
9G62056B
ROLLER SWEGE STAKING
Figure 802. Bearing Staking
D. Pitch Link Bearing Proof Load Use correct dimension tools.

CAUTION
(Ref. Figure 803)
(1). Proof load bearing installation with a

Consumable Materials force of 500-510 lbs. (226.8-231.3 Kg).
(Ref. CSPSPM)
Item Nomenclature
Outer race must not move more than
C319 Lacquer, Acrylic, Gloss Red 0.002 in. (0.051 mm).in each of the
two direction from its initial position.
Page 803
If bearing moves, maximum move pitch link with a red dot, use gloss red
ment in opposite direction must not acrylic lacquer (C319).
be more than 0.004 in. (0.102 mm).
Lacquer, Acrylic, Gloss Red (C319) (3). Put number of times bearing has been
replaced on end of housing, use perma
nent ink. No maximum number of
times bearing can be replaced, if
housing is within serviceable limits.
(2). After proof load is complete, identify
DIAL INDICATOR
OR
TRANSDUCER

LOAD HERE
LOAD APPLIED TO

BEARING OUTER RACE

HOUSING

PLATEN
9G62-057
Figure 803. ProofLoad Verification
2. Scissors Assembly Drive Link Repair A. Upper Drive Link Repair

(107)
(Ref. Figure 804)
Be careful when you remove
CAUTION link assembly, lower link can
(Ref. CSPSPM)
contact upper link and damage can occur.
Item Nomenclature (1). Remove scissors drive link assembly
(1).
C233 Chemical Coating
(2). Remove lower scissors drive link (3).
C308 Primer
NOTE: Flanged bearings have a dark brown or
C303 Finish Enamel, Black black material bonded to the bearing hole
and flange.
(3). Examine flanges of bearings (4) for
Special Tools
wear in bonded material (metal of
bearing shows through bonded materi
(Ref. CSPSPM)
al). None permitted.
Item Nomenclature
(4). Examine hole of flanged bearings (4).
T508 Bearing Removal/Installation Tool Set Maximum inner dimension 0.3755 in.
(9.54 mm).
Page 804
(5). Examine upper scissors drive link (2) (2). Remove upper scissors drive link (2).
for condition and damage. Maximum
permitted depth 0.005 in. (0.127 mm). (3). Examine hole of flanged bearings (6).
Maximum inner dimension 0.3760 in.
Chemical Coating (C233) (9.55 mm). Replace bearings as a set.
(4). Examine lower scissors drive link (3) for

condition and damage. Maximum
permitted depth 0.005 in. (0.127 mm).
(6). Make damaged area smooth and apply
chemical coating (C233). Chemical Coating (C233)
Primer (C308)

(7). Apply primer (C308). chemical coating (C233).
Finish Enamel, Black (C303)
Primer (C308)
(8). Apply black finish enamel (C303).

(6). Apply primer (C308).
(9). Install lower scissors drive link.
(10). Install scissors drive link assembly. Finish Enamel, Black (C303)
B. Lower Drive Link Repair

(Ref. Figure 804)
Be careful when you remove
CAUTION link assembly, lower link can (7). Apply black finish enamel (C303).
contact upper link and damage can occur.
(8). Install upper scissors drive link (2).
(1). Remove scissors drive link assembly
(1). (9). Install scissors drive link assembly (1).
Page 805
2
1
6
2 REF
3 REF LUG
3 5
4 (4 PL)
9G62059B
1. SCISSORS DRIVE LINK ASSEMBLY 4. BEARING, FLANGED
2. UPPER SCISSORS DRIVE LINK 5. WASHER, LAMINATED
3. LOWER SCISSORS DRIVE LINK 6. BUSHING, FLANGED
Figure 804. Scissors Drive Link Repair
C. Upper Drive Link Flanged Bearing scratch depth permitted 0.0005 inch
Removal (0.0127 mm).
(Ref. Figure 805) Chemical Coating (C233)
(1). Outboard upper drive link flanged
bearing removal.
(a). Put upper drive link (1) in a soft
jawed vise. (a). Make damaged area smooth and
apply chemical coating (C233).
(b). Cut threads in flanged bearing (2),
use 7/16 x 20 NF tapered tap. Do not D. Upper Drive Link Flanged Bearing
cut into inboard bearing. Installation
(Ref. Figure 805)
(c). Cut threads to bottom of bearing (2),
use 7/16 x 20 NF bottom tap. Do not
cut into inboard bearing. CAUTION
(d). Install scissors assembly bushing tool Flanged bearings (6) are longer than the
set (T508). Hold bolt (T508-1) and thickness of the drive link. Put a support
turn nut (T508-2) to remove bearing under drive link so bearing can go fully
(2). through drive link.
If you use waterborne primer to install
(2). Inboard upper drive link flanged bearings, do no thin primer with water.
bearing removal. Use acetone (C436).
(a). Remove inboard bearings (3). Use Primer (C308)
arbor press and support (T508-6).
(b). Remove lower end bearings (6). Use
arbor press and support (T508-6).
(3). Examine holes in upper scissor. Maxi (1). Install bearings. Install wet with
mum inner dimension 0.5001-0.5006 primer (C308). Use arbor press, punch,
in. (12.7025-12.7152 mm). Maximum plate, and support.
Page 806
(2). Remove primer from bearing surfaces. between outer edge of bearing flange
(3). Apply primer (C308) to make a fillet and drive link.
NOTE 1
2 NOTE 2
1 2
T508-1
1
T508-2
T508-3 3
T508-4
3
T508-5
NOTE 3
1 4
2
3 1
5
NOTE 4
6
NOTES:
1. START THREADS IN FLANGED BEARING WITH TAPERED TAP. 7
2. COMPLETE THREADS IN FLANGED BEARING WITH BOTTOM TAP.
3. INSTALL FLANGED BEARING REMOVAL TOOL AND REMOVE BEARINGS.
4. THESE FLANGED BEARINGS ARE LONGER THAN THE THICKNESS OF THE DRIVE LINK. 9G62084A
SUPPORT FOR DRIVE LINK MUST HAVE A HOLE LARGER THAN OUTER DIMENSION OF BEARING
SO BEARING CAN GO FULLY THROUGH DRIVE LINK.
1. UPPER DRIVE LINK 5. PLATE

2. OUTBOARD FLANGED BEARING 6. LOWER END FLANGED BEARING
3. INBOARD FLANGED BEARING 7. SUPPORT
4. PUNCH
Figure 805. Upper Drive Link Flanged Bearing
Page 807
E. Lower Drive Link Flanged Bearing to end of bearing. Add the two measure
Removal ments and make a record of them as
dimension A.
(Ref. Figure 806)
(2). Measure width of lower drive link
(1). Put lower drive link (1) in a soft jawed across where bearings are installed.
vice, point scissors stop lug (4) up. Make a record of measurement as
(2). Carefully remove bearing (2) inner dimension B.
shoulder, use a 0.375 in. (9.525 mm)
(3). Subtract dimension B from dimension
cobalt drill bit.
A to find thickness of laminated
(3). Put lower drive link on flanged bearing washer.
removal tool (T508-6) and remove
bearing with inner shoulder and (4). Remove laminates from new laminated
laminated washer (3). washer to get the necessary thickness.
(4). Put lower drive link on flanged bearing CAUTION

removal tool (T508-6), point stop lug
(4) down. Remove bearing with re Make sure laminated washer is installed
moved shoulder. under flange of one flanged bearing.
(5). Examine hole in drive link. Inner Use support tool (T508-6) to prevent
dimension must be 0.5000-0.5005 in. damage to lower drive link lug.
(12.7000-12.7127 mm). Maximum If you use waterborne primer to install
scratch depth 0.0005 in. (0.0127 mm). bearings, do no thin primer with water.
Chemical Coating (C233) Use acetone (C436).
Primer (C308)

chemical coating (C233).
(5). Install flanged bearings and laminated
F. Lower Drive Link Flanged Bearing washer. Install wet, use primer (C308).
Installation
(6). Remove primer from bearing surfaces.
(Ref. Figure 806)
(7). Apply primer (C308) to make a fillet
(1). Make a measurement of the two between outer edge of bearing flange
flanged bearings from bottom of flange and drive link.
Page 808
4
1
2
5 5
NOTES 2 AND 4 NOTES 3 AND 4
NOTE 1
1 T508-6
MEASUREMENT
3 LOWER DRIVE LINK
1
2
MEASUREMENT
BEARING (2 PL)
4
T508-6
NOTE 4
NOTES:
1. REMOVE SHOULDER FROM ONE FLANGED BEARING.
2. REMOVE BEARING, USE A 0.482 IN. (12.123 mm) PUNCH. 9G62083A
3. REMOVE OTHER BEARING, USE A 0.495 IN. (12.573 mm) PUNCH.
4. USE T508-6 BEARING SUPPORT UNDER LOWER DRIVE LINK.
1. LOWER DRIVE LINK 4. LUG

2. FLANGED BEARING 5. PUNCH
3. LAMINATED WASHER
Figure 806. Lower Drive Link Flanged Bearing
Page 809
3. Drive Link Attach Bearing Replacement drill motor. Maximum depth of cut
0.125 in. (3.17 mm).
(Ref. Figure 807)
(4). Remove bearing flange cutting tool
(T918).
Special Tools
(Ref. CSPSPM) (5). Remove drive link bearing from
Item Nomenclature swashplate (Ref. Pitch Link Bearing
T918 Bearing Flange Cutting Tool Removal procedure).
(6). Examine drive link attach hole in
A. Drive Link Attach Bearing Removal swashplate for scratches, gouges, or
tool marks. None permitted.
(1). Remove swashplate.
(7). Examine hole dimension. Maximum
0.905 in. (22.987 mm).
CAUTION
B. Drive Link Attach Bearing Installation
Bearing swaged flange must be cut off be
fore bearing removal (1). Install drive link bearing in swashplate
(Ref. Pitch Link Bearing Installation
Dimension of bearing cutter must not be
procedure).
more than 0.900000 in. (22.86000 mm).
(2). Stake drive link bearing in swashplate
(2). Install bearing flange cutting tool (Ref. Pitch Link Bearing Staking
(T918) on swashplate, put pilot of procedure).
cutter through bearing to align cutter
back up block and clamp block. (3). Proof load drive link bearing (Ref. Pitch
Link Bearing Proof Load procedure.
(3). Cut into staked flange of bearing, use
bearing flange cutting tool (T918) and a (4). Install swashplate.
Page 810
2 REF
3 5
1

4
2
9G62075A
1. DRIVE LINK ATTACH BEARING 4. BEARING FLANGE CUTTING TOOL (T918), BACK UP
2. SWASHPLATE BLOCK
3. BEARING FLANGE CUTTING TOOL (T918), CUTTER 5. CLAMP OF APPLICABLE SIZE
Figure 807. Drive Link Attach Bearing Flange Removal
Page 811
Page 812
Chapter
TRANSMISSION AND
DRIVE SYSTEM
TABLE OF CONTENTS
63-00-00 Rotor Drive System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A

1. Powertrain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Drive Subsystem . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
A. Main Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
B. Input Drive Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
C. Main Rotor Drive Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
D. Anti-Torque Fan Drive Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Figure 1.Drive System (Sheet 1 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
3. Lubrication Subsystem . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
A. Lubrication Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
B. Filter Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
C. Oil Level Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
D. Pressure Transducer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
E. Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
F. Temperature Probe/Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
G. Magnetic Chip Detector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
H. Vent/Breather . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
I. Cooling Blowers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
J. Oil Coolers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
K. Blower Ducts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Figure 2.Lubrication Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
4. Rotor Brake Subsystem . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
A. Disk . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
B. Brake Head Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
C. Hydraulic Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
D. Control Linkage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
E. Hydraulic Tubing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
F. Proximity Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Figure 3.Rotor Brake System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Fault Isolation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
1. Allowable Leakage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
2. Drive System Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Table 101.Drive System Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Figure 101.Transmission Sensors Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
Figure 102.Transmission Oil Pressure PSI to % Oil Pressure (Sheet 1 of 2) . . . 106
Page i

Figure 103.Transmission Sensors Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . 108
Figure 104.Lubrication Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
63-10-00 Drive Shafts / Clutches / Couplings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A
1. Main Rotor Drive Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
A. Main Rotor Drive Shaft Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
B. Main Rotor Drive Shaft Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
Figure 401.Main Rotor Drive Shaft and Drive Plate . . . . . . . . . . . . . . . . . . . . . . . . 402
2. Main Rotor Drive Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 403
A. Main Rotor Drive Plate Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 403
B. Main Rotor Drive Plate Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 403
3. Main Rotor Drive Shaft Upper Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 404
A. Main Rotor Drive Shaft Upper Seal Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 404
B. Main Rotor Drive Shaft Upper Seal Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 404
Figure 402.Main Rotor Drive Shaft Upper Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 404
Figure 403.Main Rotor Drive Shaft Lower Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 406
4. Main Rotor Drive Shaft Lower Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 406
A. Main Rotor Drive Shaft Lower Seal Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 406
B. Main Rotor Drive Shaft Lower Seal Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 406
Figure 404.Removal and Installation of the Input Drive Shaft Assemblies . . . . 408
5. Input Drive Shaft Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 408
A. Drive Shaft Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 408
B. Drive Shaft Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 408
Figure 405.Removal and Installation of NOTAR Fan Drive Shaft Assembly . 410
6. NOTAR Fan Drive Shaft Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 410
A. Fan Drive Shaft Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 410
B. Fan Drive Shaft Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 410
Inspection / Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601
1. Input Drive Shaft Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601
A. Center Tube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601
B. Flanges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601
C. Mounting Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601
Figure 601.Input Drive Shaft Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 602
Figure 602.Diaphragm Inspection Areas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 602
D. Diaphragms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 603
Figure 603.Inspection of NOTAR Fan Drive Shaft Assembly . . . . . . . . . . . . . . . 604
2. NOTAR Fan Drive Shaft Assembly Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 604
Page ii

A. Center Tube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 604
B. Diaphragms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 604
C. Flanges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 605
D. Mounting Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 605
3. Main Rotor Drive Shaft Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 605
A. Drive Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 605
4. Main Rotor Drive Plate Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 606
A. Drive Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 606
Figure 604.Drive Plate Pitting Inspection Areas . . . . . . . . . . . . . . . . . . . . . . . . . . . 606
B. Drive Plate Pitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 607
Figure 605.Main Rotor Drive Plate Nut Torque Sequence . . . . . . . . . . . . . . . . . . . 608
5. Main Rotor Drive Plate Nut Torque Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 608
A. Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 608
Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 801
1. Diaphragm Input Shaft Assembly Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 801
A. Blend Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 801
2. Diaphragm NOTAR Drive Assembly Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 801
A. Blend Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 801
3. Main Rotor Drive Shaft Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 802
A. Blend Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 802
Figure 801.Drive Plate Pitting Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 802
4. Main Rotor Drive Plate Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 803
A. Pitting Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 803
63-20-00 Gearboxes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A
1. Main Transmission Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
A. Transmission Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
Figure 401.Transmission Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 402
B. Transmission Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 403
Figure 402.Transmission Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 404
2. Input Pinion Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 407
A. Input Pinion Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 407
B. Input Pinion Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 407
Figure 403.Input Pinion Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 409
3. Fan Drive Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 410
A. Fan Drive Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 410
Page iii

B. Fan Drive Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 410
Figure 404.Fan Drive Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 411
4. Lubrication Pump Drive Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 411
A. Lubrication Pump Drive Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 411
B. Lubrication Pump Drive Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 412
Figure 405.Lubrication Pump Drive Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 412
5. Hydraulic Pump Accessory Drive Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 413
A. Hydraulic Pump Accessory Drive Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . 413
B. Hydraulic Pump Accessory Drive Assembly Installation . . . . . . . . . . . . . . . . . . . . . 413
Figure 406.Hydraulic Pump Accessory Drive Assembly . . . . . . . . . . . . . . . . . . . . . 414
6. Blower Drive Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 415
A. Blower Drive Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 415
Figure 407.Blower Drive Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 415
B. Blower Drive Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 415
7. Pressure Transducer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 416
A. Pressure Transducer Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 416
B. Pressure Transducer Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 416
8. Transmission Speed Pickup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 417
A. Transmission Speed Pickup Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 417
B. Transmission Speed Pickup Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 417
9. Temperature Probe and Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 418
A. Temperature Probe and Switch Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 418
B. Temperature Probe and Switch Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 418
Figure 408.Transmission Pressure Transducer, Speed Pickup, Chip Detector,
Temperature Probe & Switch and Pressure Switch . . . . . . . . . . . . . . . 419
10. Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 420
A. Pressure Switch (Low) Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 420
B. Pressure Switch (Low) Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 420
11. Chip Detector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 420
A. Chip Detector Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 420
B. Chip Detector Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 421
12. Chip Detector Screen and Valve (Housing) Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 422
A. Screen and Valve (Housing) Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 422
B. Screen and Valve (Housing) Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . 422
Inspection/Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601
1. Transmission Inspections (Area 3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601
A. Transmission Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601
Page iv

Figure 601.Transmission Mating Line Environmental Seal (Sheet 1 of 3) . . . . 602
B. Acoustic Isolator Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 605
C. Chip Detector Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 605
Table 601.Metal Particle Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 605
2. Transmission Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 606
A. Transmission Operational Test - Run-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 606
B. Transmission Operational Test - Manual Rotation . . . . . . . . . . . . . . . . . . . . . . . . . 607
C. Chip Detector Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 607
D. Transmission Serviceability Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 608
E. Transmission Flush Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 608
F. Main Transmission Lubrication Pump Filter Assembly Cleaning . . . . . . . . . . . . . 609
Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 801
1. Main Transmission Assembly Seal Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 801
A. Input Pinion Assembly Seal Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 801
Figure 801.Input Pinion Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 803
Figure 802.Input Pinion Assembly Seal Replacement - Special Tools
(Sheet 1 of 2 ) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 804
B. Fan Drive Assembly Seal and Wear Sleeve Replacement . . . . . . . . . . . . . . . . . . . . 806
Figure 803.Fan Drive Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 807
Figure 804.Fan Drive Assembly - Lockwasher and Flange Assembly Removal 808
Figure 805.Fan Drive Assembly - Wear Sleeve Replacement . . . . . . . . . . . . . . . . 810
Figure 806.Fan Drive Assembly - Oil Seal Replacement . . . . . . . . . . . . . . . . . . . . 810
C. Blower Drive Pinion Assembly Seal Replacement (On Transmission) . . . . . . . . . 811
D. Blower Drive Pinion Assembly Seal and Wear Sleeve Replacement . . . . . . . . . . . 812
Figure 807.Blower Drive Pinion Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 814
Figure 808.Blower Drive Pinion Assembly - Wear Sleeve Replacement . . . . . . 815
Figure 809.Blower Drive Pinion Assembly - Oil Seal Replacement . . . . . . . . . . 816
E. Hydraulic Pump Accessory Drive Assembly Seal and Wear Sleeve Replacement 817
Figure 810.Hydraulic Pump Accessory Drive Assembly . . . . . . . . . . . . . . . . . . . . . 819
Figure 811.Hydraulic Pump Accessory Drive Assembly -
Wear Sleeve Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 820
Figure 812.Hydraulic Pump Accessory Drive Assembly -
Oil Seal Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 820
63-21-00 Transmission Lubrication and Cooling System . . . . . . . . . . . . . . . . . . . . A
1. Oil Filler Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
A. Oil Filler Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
Figure 401.Oil Filler Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
Page v

B. Oil Filler Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
2. Lubrication Pump Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 402
A. Lubrication Pump Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 402
B. Lubrication Pump Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 402
C. Lubrication Pump Pressure Relief Valve Removal . . . . . . . . . . . . . . . . . . . . . . . . . . 403
Figure 402.Lubrication Pump Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 404
D. Lubrication Pump Pressure Relief Valve Installation . . . . . . . . . . . . . . . . . . . . . . . 405
E. Lubrication Pump Filter Impending Bypass Indicator Removal . . . . . . . . . . . . . . 405
F. Lubrication Pump Filter Impending Bypass Indicator Installation . . . . . . . . . . . 405
G. Lubrication Pump Filter Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 406
H. Lubrication Pump Filter Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 406
Figure 403.Lubrication Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 407
3. Blower Impeller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 408
A. Blower Impeller Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 408
B. Blower Impeller Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 408
Figure 404.Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 409
Figure 405.Impeller Tip Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 410
Figure 406.Blower Housing Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 411
4. Blower Housing Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 412
A. Blower Housing Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 412
B. Blower Housing Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 412
5. Heat Exchanger Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 412
A. Heat Exchanger Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 412
B. Heat Exchanger Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 413
6. Thermal Bypass Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 414
A. Thermal Bypass Valve Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 414
B. Thermal Bypass Valve Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 415
Inspection / Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601
1. Lubrication System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601
A. Lubrication System Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601
2. Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601
A. Cooling Blower Impeller and Housing Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . 601
B. Cooling Ducts Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601
C. Heat Exchanger Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601
Figure 601.Heat Exchanger and Mounts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 602
Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 801
1. Heat Exchanger Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 801
Page vi

A. Corrosion Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 801
B. Nicks and Scratches Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 801
63-22-00 Rotor Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A
Fault Isolation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
1. Rotor Brake System Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Table 101.Rotor Brake System Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Figure 101.Rotor Brake Wiring Diagram (Sheet 1 of 2) . . . . . . . . . . . . . . . . . . . . . 102
1. Rotor Brake System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 301
A. Rotor Brake Bleeding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 301
Figure 301.Rotor Brake Bleeding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 302
1. Rotor Brake Head Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
A. Rotor Brake Head Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
B. Rotor Brake Head Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
2. Rotor Brake Lining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 402
A. Rotor Brake Lining Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 402
B. Rotor Brake Lining Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 402
3. Rotor Brake Proximity Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 402
A. Rotor Brake Proximity Switch Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 402
B. Rotor Brake Proximity Switch Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 402
Figure 401.Rotor Brake Head and Rotor Brake Disk . . . . . . . . . . . . . . . . . . . . . . . 403
4. Rotor Brake Disk . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 404
A. Rotor Brake Disk Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 404
B. Rotor Brake Disk Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 404
5. Rotor Brake Control Linkage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 404
A. Rotor Brake Control Linkage Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 404
B. Rotor Brake Control Linkage Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 404
6. Rotor Brake Stow Lock Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 405
A. Rotor Brake Stow Lock Bracket Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 405
B. Rotor Brake Stow Lock Bracket Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 405
7. Rotor Brake Hydraulic Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 405
A. Rotor Brake Hydraulic Control Valve Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 405
Figure 402.Rotor Brake Control Linkage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 406
B. Rotor Brake Hydraulic Control Valve Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 407
8. Rotor Brake Hydraulic Tube Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 408
Page vii

A. Rotor Brake Hydraulic Tube Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 408
B. Rotor Brake Hydraulic Tube Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . 408
Inspection / Test / Rigging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601
1. Rotor Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601
A. Rotor Brake Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601
B. Rotor Brake Rigging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601
C. Rotor Brake Operational Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601
Figure 601.Rotor Brake Rigging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 602
Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 801
1. Rotor Brake Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 801
A. Rotor Brake Head Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 801
B. Rotor Brake Disk Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 801
63-30-00 Main Rotor Static Mast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A
1. Main Rotor Static Mast Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
A. Static Mast Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
Figure 401.Static Mast Lifting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
B. Static Mast Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
Figure 402.Main Rotor Static Mast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 402
2. Truss Strut Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 403
A. Left Hand Forward Truss Strut Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 403
B. Left Hand Forward Truss Strut Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 403
C. Left Hand Middle Forward Truss Strut Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . 403
D. Left Hand Middle Forward Truss Strut Installation . . . . . . . . . . . . . . . . . . . . . . . . 403
E. Left Hand Middle Aft Truss Strut Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 404
F. Left Hand Middle Aft Truss Strut Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 404
G. Left Hand Aft Truss Strut Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 404
H. Left Hand Aft Truss Strut Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 404
I. Right Hand Forward Truss Strut Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 404
J. Right Hand Forward Truss Strut Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 405
K. Right Hand Middle Forward Truss Strut Removal . . . . . . . . . . . . . . . . . . . . . . . . . . 405
L. Right Hand Middle Forward Truss Strut Installation . . . . . . . . . . . . . . . . . . . . . . . 405
M. Right Hand Middle Aft Truss Strut Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 405
N. Right Hand Middle Aft Truss Strut Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 405
O. Right Hand Aft Truss Strut Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 406
P. Right Hand Aft Truss Strut Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 406
Page viii

3. Truss Deck Fitting Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 406
A. Left Hand Forward Truss Deck Fitting Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . 406
B. Left Hand Forward Truss Deck Fitting Installation . . . . . . . . . . . . . . . . . . . . . . . . . 406
C. Left Hand Aft Truss Deck Fitting Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 407
D. Left Hand Aft Truss Deck Fitting Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 407
E. Right Hand Forward Truss Deck Fitting Removal . . . . . . . . . . . . . . . . . . . . . . . . . . 407
F. Right Hand Forward Truss Deck Fitting Installation . . . . . . . . . . . . . . . . . . . . . . . 408
G. Right Hand Aft Truss Fitting Deck Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 408
H. Right Hand Aft Truss Fitting Deck Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 408
4. Mixer Pivot Support Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 409
A. Mixer Pivot Support Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 409
B. Mixer Pivot Support Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 409
5. Actuator Support Tie Strap Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 409
A. Actuator Support Tie Strap Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 409
B. Actuator Support Tie Strap Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 409
6. Actuator Support Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 409
A. Actuator Support Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 409
B. Actuator Support Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 409
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601
1. Main Rotor Static Mast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601
A. Main Rotor Static Mast Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601
Figure 601.Static Mast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601
B. Mixer Pivot Support Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 801
1. Main Rotor Static Mast Support Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 801
A. Main Rotor Static Mast - White Corrosion Repair . . . . . . . . . . . . . . . . . . . . . . . . . . 801
B. Main Rotor Static Mast -Material Corrosion Repair . . . . . . . . . . . . . . . . . . . . . . . . 802
Figure 801.Static Mast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 803
C. Main Rotor Static Mast Inner Surface-Pitting Corrosion Repair . . . . . . . . . . . . . 803
Figure 802.Main Rotor Support Static Mast Pitting Repair . . . . . . . . . . . . . . . . . 805
D. Main Rotor Mast Base-Paint Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 806
Page ix

Page x
Section
630000
Rotor Drive System
ROTOR DRIVE SYSTEM

1. Powertrain landing and to prevent windmilling of the
rotor in high wind conditions.
The powertrain distributes power from each
engine to the Main Rotor, NOTAR Anti- A. Main Transmission
Torque System, Hydraulic Pumps, Lubrication
The main transmission is a self contained wet
Pump and Oil Cooler Blowers. Power is
sump design. Externally it consists of a forged
normally provided by two (2) engines, however
aluminum alloy Top Case Assembly that
in case of an emergency, in-flight shutdown or
attaches the transmission assembly to the
during ground operation, it can be provided by
Static Mast Base Assembly, and cast alumi
a single engine.
num alloy Main Case assembly that contains
the gears, bearings and oil.
2. Drive Subsystem
The transmission uses spiral bevel gears to
(Ref. Figure 1) change direction of rotation and provide the
speeds for the Anti-Torque Drive, Hydraulic
The drive subsystem distributes engine power, Pump Drive, Oil Cooler Drive and internally
to the correct usable speeds to the Main Rotor, driven Oil Pump Drive quills. A combination of
Anti-Torque, Hydraulic Pumps, Lubrication spiral bevel gears and epicyclic (planetary)
Pump and Oil Cooler Blowers. The Drive spur gears are used to change rotational
Subsystem consists of the following: direction and speed reduction for the Main
Rotor.
Main Transmission - changes engine output
speed and direction to provide power at the The transmission changes the Engine Reduc
correct angles and speeds. tion Gearbox output/Main Transmission input
speed by the ratios shown in the following list.
Input Drive Shafts - two (2) drive shafts, The speeds shown are only under normal 100
one from each engine speed Reduction % (6,000 rpm) input speed condition.
Gearbox, connects engines to the Main
Transmission. 392 rpm - Main Rotor output speed
6,000 rpm - Hydraulic Pump Drive speed
Main Rotor Drive Shaft - transmits power
from the Transmission to the Main Rotor 10,615 rpm - Oil Cooler Blower speed
through the Main Rotor Drive Plate.
5,412 rpm - Lubrication Pump speed
Anti-Torque Fan Drive Shaft - transmits
main transmission torque to the Anti-Torque 5,412 rpm - Anti-Torque drive speed
fan. There are no life limited components when the
transmission is used at certified operating
Isolators - dampens transmission noise that
power conditions.
would normally be carried between the top
case and Static Mast Base through the The transmission main case and drive quill
structure to the fuselage. assemblies are master shimmed to allow
individual removal of each quill for repair or
Oil Cooler Assemblies - air/oil heat ex replacement.
changers used to maintain the correct operat
ing temperature for the transmission oil and Input Quill Assembly - attaches the input
components. drive shaft to each input quill and contains a
overrunning sprag clutch. The clutch decouples
Rotor Brake Assembly - is attached to the the transmission from the engine during
lower portion of the transmission case housing engine start up, in the event of an engine
and is used to stop the main rotor after in-flight shutdown and/or during autorotation.
Page 1
Hydraulic Pump Drive Quill Assembly - C. Main Rotor Drive Shaft

accepts an AND 20002 type pad and contains
a dry spline which drives the hydraulic pump. The main rotor drive shaft transmits power
between the planetary carrier and the main
Oil Cooler Blower/Fan Drive Quill rotor drive plate. It has a crowned spline at
Assembly - provides for attaching the fan each end that allows angular misalignment
shroud and mounting the fan impeller. between the carrier spline and the drive plate
spline. This allows for manufacturing toler
Oil Pump Drive Quill Assembly - accepts ances and flight load bending of the static
the oil pump/filter assembly. mast.
D. AntiTorque Fan Drive Shaft
B. Input Drive Shaft
The drive shaft transmits power from the
Each drive shaft transmits power from the main transmission Anti-Torque fan drive quill
engine reduction gearbox to the main trans to the Anti-Torque fan assembly. It consists of
mission input quill. They consist of flexible flexible diaphragm couplings attached at each
diaphragm couplings attached at each end of a end of the shaft. Each flexible coupling allows
shaft. Each flexible coupling allows a maxi a maximum angular ( 1/2 degree) and axial (
mum angular ( 1/2 degree) and axial ( 1/8 1/8 inch) misalignment between the Anti-
inch) misalignment between the engine output Torque fan drive quill output flange and the
flange and the transmission input flange. Anti-Torque fan assembly attaching flange.
Each end of the drive shaft contains an Each end of the drive shaft contains an
anti-flail device to prevent damage to the anti-flail device to prevent damage to the
surrounding area or components in the surrounding area or components in the
unlikely event of a failure of the diaphragm. unlikely event of a failure of the diaphragm.
Page 2
Original 63-00-00
MAIN ROTOR
DRIVE SHAFT
STATIC MAST
SUPPORT ASSEMBLY
PRESSURE
TRANSDUCER
STRUT INPUT
ASSEMBLY DRIVE SHAFTS
BLOWER HOUSING
ASSEMBLY
LUBRICATION
PUMP
DECK FITTING
TRANSMISSION
ASSEMBLY HYDRAULIC ASSEMBLY
PUMP DRIVE NOTAR FAN
DRIVE SHAFT
TEMPERATURE
PROBE AND
SWITCH
9G63-022-1
Figure 1. Drive System (Sheet 1 of 2)
Page 3
63-00-00 Original
EXHAUST DUCT
INTERCONNECT DUCT
OIL COOLER
AIRFRAME
DECK
INLET DUCT
STATIC MAST SUPPORT ASSEMBLY AND

MAIN ROTOR DRIVE SHAFT REMOVED FOR CLARITY.
PRESSURE SWITCH
(LOW)
OIL LEVEL
INDICATOR
MAGNETIC
CHIP DETECTOR
VIEW ROTATED
9G63-022-2
Figure 1. Drive System (Sheet 2 of 2)
Page 4
Original 63-00-00
3. Lubrication Subsystem A. Lubrication Pump
(Ref. Figure 2) An unregulated pressure positive displacement

gerotor pump used to circulate the oil through
The transmission is cooled by ambient air the filter, oil coolers and transmission oil
passing over the external housings and by passages and jets.
pressurized oil lubrication of the internal B. Filter Unit
components. The oil is cooled by using two (2)
transmission driven fans to draw outside air A dual stage replaceable filter contained
through two (2) air/oil heat exchangers within a cast aluminum alloy located inside
through which the oil is circulated and cooled. the lubrication pump is used to eliminate
particles contained in the lubricant. The
Oil operating temperature is maintained below replaceable first stage filter is a 75 micron
230 F (159.7 C). nominal element and the replaceable second
stage is a 3 micron nominal element. The unit
The lubricating subsystem consists of the contains a bypass system to allow continued
following components: unfiltered pressurized lubrication in the event
the filters become clogged. The bypass system
Lubrication Pump - pressurizes and is designed to prevent debris already trapped
circulates oil from the main transmission in the filter elements from being reintroduced
sump through the gear train. into the transmission.
Filter Unit - bypass filter eliminates particles C. Oil Level Indicator

from the lubricating oil. A clear prismatic window is located on the
lower right side portion of the main case
Oil Level Indicator - a visual sight gage housing. It is used to visually indicate the
mounted on the main transmission. static level of lubricant contained within the
sump area of the transmission. The window is
Pressure Transducer - sends an oil pressure surrounded by a frame which is marked with
signal to the IIDS display. the proper lubrication service level.
Pressure Switch - illuminates the main D. Pressure Transducer
transmission low oil pressure light on the IIDS
display. A pressure transducer mounted on the main
transmission measures main transmission oil
Temperature Probe/Switch - measures oil pressure. The transducer sends a signal to the
temperature and illuminates the oil overheat main transmission oil indicator on the IIDS
light on the IIDS display. display. The IIDS monitors the oil pressure. If
oil pressure drops below 35 psig at 100% Rotor
Magnetic Chip Detector - detects metal rpm (NR) a caution light illuminates. If oil
particles in the main transmission oil. pressure drops below 30 psig at 100% NR, or
16 psig at 65% NR (idle), a warning light
Vent/Breather - eliminates gear case heat illuminates on the IIDS display.
and oil vapors from the lubrication system. E. Pressure Switch
Cooling Blowers - provide cooling air to the A pressure switch mounted on the main
oil coolers. transmission completes an electrical circuit to
illuminate the main transmission low oil
Oil Coolers - provide a heat exchange with pressure light on the IIDS display. The switch
ambient air to cool the transmission lubricat completes an electrical circuit when oil
ing oil. pressure decreases below 20 psig at 100% NR.
The completed electrical circuit illuminates a
Blower Ducts - provide inlet and exhaust warning light on the IIDS display. The
passages for ambient air to enter and exit the warning light is disabled below 85% NR,
cooling blowers. regardless of current psig reading.
Page 5
F. Temperature Probe/Switch I. Cooling Blowers

A resistive temperature probe/switch is Two cooling blowers are mounted on the main
mounted on the main transmission to measure transmission housing. The blowers are driven
the oil temperature. The probe/switch sends a by the blower drive quills to provide additional
signal to the main transmission temperature cooling air to the main transmission oil coolers.
indicator on the IIDS display. The temperature
readout on the IIDS display is a numeric J. Oil Coolers
value.
The probe/switch functions to complete an Two oil coolers are used to cool main transmis
electrical circuit to illuminate a light on the sion oil. Ambient air is drawn in by each
IIDS display. When oil temperature exceeds cooling blower to circulate air over the fins of
199.4 F (93 C) for CAUTION light and the oil cooler cores. The transmission oil is
230 F (110 C) for WARNING light. routed through one of the two oil coolers cores.
Oil from engines are also routed to the other
G. Magnetic Chip Detector core of oil coolers for cooling purposes.
A magnetic chip detector is mounted on the K. Blower Ducts
transmission housing to detect metal particles
in the oil system. An IIDS controlled burn-off Each cooling blower has an inlet, interconnect,
feature performs burning-off of inconsequen and exhaust duct. The inlet duct routes
tial pieces of metals collected on the chip ambient air to the oil cooler. The inlet duct has
detector base. After five successful chip clear a mesh screen over the opening. The duct
events, the Transmission Chip Burn count attaches to the oil cooler and the main
over limit (Bit 7 ACFTFALT word) is set and a transmission deck. The interconnect duct
CHECK FAULT LOG message displays. attaches to the inlet port of the cooling blower
H. Vent/Breather scroll. The duct routes air passing through the
oil cooler to enter the cooling blower. The
An ambient vent/breather is located above the exhaust duct attaches to the exhaust port of
oil level indicator. The vent/breather provides the cooling blower scroll and the main trans
an ambient vent for gear case heat and oil mission deck. The duct routes cooling blower
vapors. The vent/breather also serves as a exhaust air overboard.
filler cap to service the lubrication system with
oil.
Page 6
PRESSURE
RELIEF VALVE
OIL COOLER
PRESSURE
TRANSDUCER
PRESSURE
SWITCH
OIL IN
FILTER TEMPERATURE TEMPERATURE

LUBE
TRANSDUCER SWITCH
PUMP
OIL COOLER
PRESSURE
RELIEF VALVE
9G63-023
Figure 2. Lubrication Schematic

4. Rotor Brake Subsystem Hydraulic Control Valve - provides
pressurized hydraulic fluid to actuate the
(Ref. Figure 3) brake head assembly.
The rotor brake subsystem is a hydraulically
operated single disc two cylinder brake. The
rotor brake decreases rotation of the main Control Linkage - control handle that causes
rotor and Anti-Torque fan during engine a pressure increase or decrease from the
shutdown. The rotor brake is applied after hydraulic control valve to the brake head
engine shutdown, when main rotor rpm assembly.
reaches 70% or less. The rotor brake subsys
tem consists of the following components:
Hydraulic Tubing - transfers hydraulic fluid
Disk - braking surface that is attached to the from the hydraulic control valve to the brake
Anti-Torque fan drive quill. head assembly.
Brake Head Assembly - houses the calipers,

pistons, steel carriers, and linings that are Proximity Switches - monitor position of
hydraulically actuated to engage the disk. each brake head assembly piston.
Page 7
63-00-00 Original
A. Disk C. Hydraulic Control Valve
The disk is mounted on the Anti-Torque fan The hydraulic control valve is located on the
drive flange of the Anti-Torque Fan drive main transmission deck. The control valve is a
quill. The disk is of one piece steel construc reservoir for hydraulic fluid (C112) used to
tion, with four equally spaced mounting holes operate the rotor brake subsystem. A remov
and is factory balanced. able filler cap is located on top of the control
valve, for servicing.
B. Brake Head Assembly When the rotor brake handle in the crew
station is pulled, the control valve internal
The brake head assembly is mounted on the metering circuit pressurizes fluid to the brake
main transmission housing. The brake head head assembly.
assembly consists of a housing, calipers, steel
carriers, and linings. The housing is made of D. Control Linkage
cast aluminum and anodized to prevent The control linkage is located in the cockpit
corrosion. Two caliper pistons are mounted in ceiling above the pilot seat. The handle has a
the housing. The steel carriers, and linings are lockout feature that prevents the handle from
seated in the housing and is moved by the being inadvertently operated. To apply the
opposed caliper pistons. rotor brake, the control handle is rotated and
pulled down. The control handle moves the
The brake head assembly receives hydraulic hydraulic control valve metering circuit control
pressure and fluid flow from the hydraulic rod to pressurize the system. The control valve
control valve. When fluid pressure is in pressurizes the brake head assembly to a
creased, the opposed caliper pistons in the maximum pressure of 500 psig.
brake head housing extend outward toward
each other. Each piston contacts a steel carrier When the control handle is pushed upward,
and lining that presses against the disk. This the control valve internal metering circuit
engagement causes friction between the disk decreases pressure, while maintaining a back
and linings, resulting in a braking action. pressure of 10 psig.
E. Hydraulic Tubing
The braking action causes the disk, Anti-
Torque fan drive quill, Anti-Torque fan drive The hydraulic tubing is stainless steel high
shaft, Anti-Torque fan, main transmission, pressure tubing. The tubing routes hydraulic
main rotor drive shaft, and main rotor to stop fluid from the hydraulic control valve to the
rotating. When fluid pressure is decreased, the break head assembly.
pistons retract into the brake head housing by
a return spring. The linings disengage the disk F. Proximity Switches
and returns to the disk clearance dimension
Two proximity switches are installed in the
maintained by a self adjusting mechanism.
brake head assembly. The switches indepen
dently monitor the position of each brake
Each lining has a wear indicator. When the assembly piston.
wear indicator on a lining becomes exposed,
that is a visual indication to replace the lining. The switches complete an electrical circuit to
the IIDS display. The electrical circuit illumi
Bleeder assemblies are located on the brake nates the Rotor Brake light on the IIDS
head housing. The bleeder assemblies provide display during rotor brake subsystem applica
a means to bleed air from the hydraulic lines tion. The Rotor Brake light is extinguished
and brake head housing internal ports. when the rotor brake subsystem is released.
Page 8
HYDRAULIC
TUBE
CONTROL LINKAGE
HYDRAULIC
CONTROL VALVE
DISK
BRAKE HEAD
ASSEMBLY
PROXIMITY
SWITCH
PROXIMITY
SWITCH VIEW ROTATED
9G63-024
Figure 3. Rotor Brake System
Page 9/(10 blank)

63-00-00 Original
ROTOR DRIVE SYSTEM
FAULT ISOLATION
1. Allowable Leakage Troubleshooting tables should be used with the

A visual change in oil level of 0.125-0.250 simplified system schematics, electrical wiring
inch (3.175-6.35 mm) or approximately diagrams, serviceability tests and other
one-half quart (0.473 liters) of oil, over a detailed procedures in this and other chapters
period of 6 running hours. of the manual.
2. Drive System Troubleshooting Comprehensive wiring diagrams are available
(Ref. Figure 101 and Figure 103) in the Rotorcraft Maintenance Manual
brief summary of drive system faults, which
may be encountered (Ref. Table 101).
Table 101. Drive System Troubleshooting

Overspeed Perform appropriate Main Rotor 055000

Overspeed inspection
Overtorque Perform appropriate 055000

Overtorque inspection
Excessive oil leak from input Damaged seal. Replace pinion Assy or perform 632000
pinion assembly. Input Pinion Assembly Seal
Replacement.
Poor fit between seal and Replace pinion Assy or perform 632000
shaft. Input Pinion Assembly Seal
Replacement.
Excessive axial displace- Perform Engine to Transmis- 710000
ment at input flanges. sion Alignment.
Impending bypass indicator Faulty bypass indicator. Replace impending bypass 632100
popped in less than 100 indicator.
hours since filter change.
Lubrication pump impending Clogged oil filter. Reset indicator. On second 632100
bypass indicator popped. popup, replace 3 micron
transmission filter.
Clean 75 micron transmission 120000

filter
test chip detector. 632000
Loud bang after engine Cooling duct oil canning;

shutdown.
Clogged heat exchanger. Clean heat exchanger. 202000
Clogged cooling inlet. Clean inlet duct. 202000
Page 101
Table 101. Drive System Troubleshooting (Cont.)

XMSN HI OIL TEMP Transmission oil level low. Service transmission. 120000
WARNING or CAUTION
illuminated and/or XMSN OIL Faulty transmission heat Test relative temperature of 632100
TEMP C DD indicates high. exchanger. heat exchanger and two oil
hoses from transmission to
heat exchanger immediately
after engine shutdown. If hoses
and heat exchanger are cool
relative to the transmission
case, replace heat exchanger.
Clogged oil filter. Replace transmission oil filter. 632100

Clogged heat exchanger. Clean heat exchanger. 202000
Clogged cooling inlet. Clean inlet duct. 202000
Faulty lubricating pump Replace lubrication pump drive 632000
drive. assembly.
Faulty blower impeller. Replace blower drive assembly. 632100
Faulty thermal bypass valve. Replace thermal bypass valve. 632100
XMSN HI OIL TEMP Open wire between: P412D Test and repair wiring. 980000
WARNING illuminated, but and P104M, P412E and
XMSN HI OIL TEMP ground.
WARNING not displayed on
IIDS A/N display. Faulty temp probe & switch Replace temp probe & switch 632000
transducer. transducer.
Loss of XMSN OIL TEMP Faulty temp probe & switch Replace faulty temp probe & 632000
reading. transducer. switch transducer.
Open wire between: P412A Test and repair wiring. 980000
and P10329, P412B and
P10330 or P412C and
P10331.
XMSN LOW OIL TEMP Faulty thermal bypass valve. Replace thermal bypass valve. 632100
CAUTION illuminated and/or
XMSN OIL TEMP C DD
indicates low.
No XMSN OIL PRESS Loss of 7.5 Vdc excitation to Test P411 pins A and B for 7.5 980000
%PSI DD with engines pressure switch. Vdc. If no voltage, test and
running. repair wiring.
Open wire between: P411C Test and repair wiring. 980000
and P10221 or P411D and
P10222.
Faulty oil pressure Replace oil pressure 632000
transducer. transducer.
Page 102

XMSN LOW OIL PRESS Replace 3 micron transmission 632100
CAUTION and/or WARNING lubrication pump filter
segment illuminated
if condition persists, replace 75 632100
micron filter
XMSN LOW OIL PRESS Shorted wire between: P413 Test and repair wiring. 980000
CAUTION segment to ground or
illuminated, but oil pressure P105 to ground.
in XMSN OIL PRESS %PSI
DD within limits. Pressure switch (Low) stuck Replace pressure switch (Low). 632000
closed.
Irregular or extreme Faulty pressure transducer Replace pressure transducer. 632000
transmission oil pressure
fluctuations at 100% NR. Open or loose wiring Test and repair wiring. 980000
CAUTION and/or WARNING Transmission serviced Drain oil until level is 1/4 below 120000
illuminated above FULL mark but 3/4 above the Fill mark. If
problem persists, proceed with
following steps.
Drain transmission (while oil is 120000
still warm).
Remove chip detector and 632000
screen / valve assembly
(housing) and clean.
Replace 3 micron lubrication 632100
pump filter, clean or replace 75
micron filter, and clean pump
filter housing.
Service transmission to proper 120000
level.
XMSN LOW OIL PRESS Open wire between: P413A Test and repair wiring. 980000
%PSI, but no CAUTION and P105L or P413B and
segment illuminated. GS401B.
XMSN LOW OIL PRESS Open wire between: P413A Test and repair wiring. 980000
%PSI, but no low WARNING and P105L or P413B and
segment illuminated. GS401B.
Page 103

CHIPS DD on IIDS. Magnetic chips on chip Inspect chip detector for metal 632000
detector. particles. Table 601
Inspect filter impending bypass 632000
(popup) indicator
If a second illumination Perform Transmission 632000
(within 50 hours of a first) or Serviceability Test.
repetitive chip light
illumination occurs.
Faulty wiring between chip Test and repair wiring. 980000
detector and IIDS.
Faulty chip detector. Replace chip detector. 632000
ACFTFALT=7 After five successful chip Inspect chip detector for metal 632000
clear events, the transmis- particles. Table 601
sion chip burn count over
limit (ACFTFALT=7) is set
and a CHECK FAULT LOG CSP900RMM
message displays. Clear Fault Log. 2S1/S2/S3
TQ SPLIT EXCEED High rate of torque change Pilot clears IIDS AN display. NA
displayed on IIDS A/N with one engine slightly No maintenance action
display resulting in lagging behind the other, required.
Exceedance Log parameter or When Exceedance Data is
XSMN TQ SPLIT operating in Manual Mode downloaded, XSMN TQ SPLIT
with a large torque split and recording is not required.
switching to Auto Mode
without matching torques
first.
Page 104
5
6
7
8
10
9
9G63-030
1. PRESSURE TRANSDUCER 6. CONNECTOR (P412)
2. CONNECTOR (P411) 7. PRESSURE SWITCH (LOW)
3. SPEED PICKUP (TRANSMISSION ) 8. CONNECTOR (P413)
4. CONNECTOR (P417) 9. CHIP DETECTOR
5. TEMP PROBE & SWITCH 10. CONNECTOR (P415)
Figure 101. Transmission Sensors Location
Page 105
Transmission Oil Pressure to % Oil Pressure Nr @ or Below 85% 0-200 PSI and 0-120 %PSI
120
HIGH PRESSURE CAUTION @
100 PSI AND 100% PSI
110 NOTE 2 AND 3
100 HIGH PRESSURE WARNING @

90 NOTE 1 AND 3
80
LOW PRESSURE CAUTION @
70 NR 50% AND BELOW 24 PSI AND 75% PSI
NOTE 2 AND 3
60
50
LOW PRESSURE WARNING @
NR 51%-85% 16 PSI AND 50% PSI
40 NOTE 3 AND 4
NOTES: HIGH PRESSURE ENUNCIATIONS ARE ILLUMINATED ON INCREASING PRESSURE.

30 LOW PRESSURE ENUNCIATIONS ARE ILLUMINATED ON DECREASING PRESSURE.
1. WARNING DISPLAY AFTER FIVE (5) SECOND DELAY.
20 2. WHEN IN DISPLAY BY EXCEPTION MODE, THE % PSI DIGITAL DISPLAY
ACTIVATES WHEN % PSI IS WITHIN 2% OF HIGH OR LOW CAUTION.
3. SIGNAL SOURCE IS OIL PRESSURE TRANSDUCER. TRANSDUCER IS 0-200 PSIG
10 WITH 0-75 mv OUTPUT, 75 mv = 200 PSIG.
4. THERE IS NO LOW PRESSURE WARNING WITH NR 50% OR LESS.
0
0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170 180 190 200
PSI
9G63-035-1
Figure 102. Transmission Oil Pressure PSI to % Oil Pressure (Sheet 1 of 2)
Page 106
Transmission Oil Pressure to % Oil Pressure Nr @ or Above 86% 0-200 PSI and 0-120 %PSI
120
HIGH PRESSURE CAUTION @
110 100 PSI AND 100% PSI
NOTE 2 AND 3
100 HIGH PRESSURE WARNING @

90 NOTE 1 AND 3
80
LOW PRESSURE CAUTION @
34 PSI AND 75% PSI
70 NOTE 2 AND 3
60 LOW PRESSURE WARNING @

29 PSI AND 65% PSI
NOTE 3 AND 5
50
NOTES: HIGH PRESSURE ENUNCIATIONS ARE ILLUMINATED ON INCREASING PRESSURE.
40 LOW PRESSURE WARNING @ LOW PRESSURE ENUNCIATIONS ARE ILLUMINATED ON DECREASING PRESSURE.
20 PSI AND 44% PSI 1. WARNING DISPLAY AFTER FIVE (5) SECOND DELAY.
NOTE 4 AND 5 2. WHEN IN DISPLAY BY EXCEPTION MODE, THE % PSI DIGITAL DISPLAY
30 ACTIVATES WHEN % PSI IS WITHIN 2% OF HIGH OR LOW CAUTION.
3. SIGNAL SOURCE IS OIL PRESSURE TRANSDUCER. TRANSDUCER IS 0-200 PSIG
WITH 0-75 mv OUTPUT, 75 mv = 200 PSIG.
20 4. SIGNAL SOURCE IS OIL PRESSURE SWITCH. SWITCH CLOSES @ 20 PSI AND
OPENS @ 25 PSI.
10 5. LOW PRESSURE WARNING IS ACTIVATED BY EITHER PRESSURE TRANSDUCER
OR PRESSURE SWITCH.
0
0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170 180 190 200
PSI
9G63-035-2
Figure 102. Transmission Oil Pressure PSI to % Oil Pressure (Sheet 2 of 2)
Page 107
A403 A2
MAIN TRANSMISSION IIDS
J5 P411 W129 P157 J157 P102 J2
Q Q Q W123 Q
A 1 19 HI XMSN OIL
PRESS EXCIT
B 2 20 LO
OIL PRESSURE
C 3 21 HI XMSN OIL
D 22 LO PRESS
4
A612
W123 W122
P171 J1 J3 P170 P103 J3
J3 P417 P P P P
P P P P
A 5 21 22 36 NR HI
NR SPEED SENSOR
B 6 22 23 37 NR LO
J4 P412 T T T T T T
T T
C 11 25 69 29 LO 2
OIL TEMP SENSOR 30 LO 1 XMSN OIL TEMP
B 12 26 70
A 13 27 71 31 HI
D 14
OIL TEMP HI
E E
W122 P105 J5
J1 P413
OIL PRESSURE LO A 15 28 21 L XMSN OIL PRESS LO

B E
C SPARE
J2 P415
CHIP A 16 29 24 K XMSN CHIP DETECTOR
DETECTOR
B E
W123 P104 J4
C SPARE
M XMSN OIL TEMP HI
9G63-021B
Figure 103. Transmission Sensors Wiring Diagram
Page 108
PRESSURE
RELIEF VALVE
OIL COOLER
PRESSURE
TRANSDUCER
PRESSURE
SWITCH
OIL IN
FILTER TEMPERATURE TEMPERATURE

LUBE
TRANSDUCER SWITCH
PUMP
OIL COOLER
PRESSURE
RELIEF VALVE
9G63-023
Figure 104. Lubrication Schematic
Page 109
Page 110
Section
631000
Drive Shafts /
Clutches / Couplings
DRIVE SHAFTS/CLUTCHES/COUPLINGS
1. Main Rotor Drive Shaft Make sure the correct lubricat
CAUTION ing oil specification for trans
A. Main Rotor Drive Shaft Removal
mission before starting work. Do not mix
(Ref. Figure 401) different lubricating oils, damage will re
The main rotor drive shaft cover sult. (ref. Section 12-00-00, Table 1.)
CAUTION retains a spring-loaded drive
shaft. Exercise care during removal of the NOTE: Make sure bevel on wear sleeve (17)
cover. Injury to personnel can occur. points down after installation.
(1). Remove sealing compound from bolts
(2) and nuts (5). (1). If removed, install wear sleeve (17) and
spacer (18). (Wear sleeve has a small
(2). Remove bolts (2), countersunk washers bevel on the inside for ease of installa
(3), washers (4), and nuts (5). tion.)
(3). Remove main rotor drive shaft cover (1)
and discard O-ring (6). Grease, Synthetic (C110)
The spring and the carrier sup
CAUTION port lockwasher (ref. Section
63-20-00, Figure 402) at the bottom of the
drive shaft may become adhered to the drive
shaft with grease, causing them to be re
moved with the drive shaft. When removing (2). Pack upper and lower spines of drive
the drive shaft, while preventing the trans shaft with synthetic grease (C110).
mission from rotating, rotate the drive shaft
to brake the grease seal to the spring. (3). Apply a film of synthetic grease (C110)
over spacer (18) and lower seal sleeve
(4). Carefully lift drive shaft (10) from surface (17).
static mast (11).
NOTE: In replacing drive shaft with like new NOTE: Carefully lower drive shaft (10). The
item, perform following step. drive shaft lower spline must pass through a
(5). Remove damper assembly retaining lower seal (6, Figure 403) before engaging
ring (8). Remove damper (7) and transmission spline.
discard o-ring (9).
(4). Carefully lift drive shaft (10, ref.
(6). Remove wear sleeve (17) and spacer Figure 401) and install in static mast
(18). (11).
B. Main Rotor Drive Shaft Installation
(Ref. Figure 401) Oil, Lubricating (C122)
(Ref. CSPSPM)
Item Nomenclature
C110 Grease, Synthetic
C101 Lubricant, Solid Film (5). Lubricate new O-ring (9) with proper
C211 Sealing Compound, Corrosion Inhibitive lubricating oil and install on damper
C106 Oil, Lubricating assembly (7).
or
C122 Oil, Lubricating (6). Install damper (7) and retaining ring
(8).
Page 401

1
2 (6 PL)
(NOTES)
3 (6 PL)
6

18
8

8
1 3

9
6

10
7

9
5 17

4 2
7 10

12
13 (10 PL)
VIEW LOOKING DOWN AT TOP

OF HUB TO SHOW TORQUE
SEQUENCE EXAMPLE
4 (6 PL)
5 (6 PL)
20 (DO NOT INSTALL)
16
19
14 (10 PL)
15 (10 PL)
NOTES:
1. MAIN ROTOR DRIVE PLATE ATTACH
NUT TORQUE SEQUENCE. 11
2. START NUMBERS AT ONE OF THE 10 HOLES.
9G63-001G
1. MAIN ROTOR DRIVE SHAFT COVER (REF. IPL, 11. STATIC MAST
620000, FIG. 2) 12. MAIN ROTOR DRIVE PLATE
2. BOLT 13. BOLT
3. COUNTERSUNK WASHER 14. WASHER
4. WASHER 15. NUT
5. NUT 16. ORING (POST SL900066)
6. ORING 17. WEAR SLEEVE
7. DAMPER 18. SPACER
8. RETAINING RING 19. MAIN ROTOR HUB
9. ORING 20. FRETTING BUFFER DO NOT INSTALL
10. MAIN ROTOR DRIVE SHAFT
Figure 401. Main Rotor Drive Shaft and Drive Plate
Page 402
(7). Lubricate new O-ring (6) with lubricat B. Main Rotor Drive Plate Installation
ing oil (C106) and install on drive shaft
cover (1). (Ref. Figure 401)
Lubricant, Solid Film (C101)
(Ref. CSPSPM)
Item Nomenclature
(8). Lubricate bolts (2) with solid film
lubricant (C101). (1). Number torque sequence on drive plate
(12) with a permanent marker.
NOTE: If minimum torque does not meet re NOTE: Do not install fretting buffer (20). Fret
quirements, both nuts (5) and bolts (2) must ting buffer is not necessary and its removal
be replaced. will make it easier to apply the environmen
tal seal around main rotor hub and drive
(9). Install bolts (2), countersunk washers plate.
(3), washers (4) and nuts (5). Torque Oil, Lubricating (C122)
nuts (5) plus locking (run-on) torque
(ref. CSP-SPM).

(2). Lubricate new O-ring (16) with
lubricating oil (C122).
(3). Install O-ring (16).
(4). Install drive plate (12).
(10). Using sealing compound (C211) seal Lubricant, Solid Film (C101)
parting line of drive shaft cover (1), bolt
heads (2) and nuts (5) (ref. CSP-SPM).
2. Main Rotor Drive Plate (5). Lubricate bolts (13) with solid film
lubricant (C101).
A. Main Rotor Drive Plate Removal NOTE:
Record locking (run-on) torque of each
(Ref. Figure 401) nut (15) in Rotorcraft Log Book.
If a nut has less than 6.5 in-lb (0.73 Nm)
(1). Remove main rotor drive shaft (ref. locking torque, that nut (15) and related
Section 63-10-00). bolt (13) must be replaced.
Record location of nuts (15) that have less
(2). Remove adhesive from bolts (13) and than 6.5 in-lb (0.73 Nm) locking torque
nuts (15). in Rotorcraft Log Book.
(6). Install bolts (13), washers (14), and
(3). Remove bolts (13), washers (14), nuts nuts (15).
(15). and drive plate (12).
(a). Find locking (run-on) torque of each
nut (15) (ref. CSP-SPM, Section
(4). Discard O-ring (16). 20-10-00, Torque Values).
Page 403
(b). Torque nuts (15) in sequence, 1 thru 3. Main Rotor Drive Shaft Upper Seal
10, to 80 to 90 in-lb (9.04 to 10.17
A. Main Rotor Drive Shaft Upper Seal
Nm) plus (+) locking torque. Removal
(Ref. Figure 402)
(c). Torque nuts (15) again in sequence, 1
(1). Remove main rotor drive plate (ref.
thru 10, to 160 to 180 in-lb (18.08
Section 63-10-00).
to 20.34 Nm) plus (+) locking
torque. (2). Remove spiral retaining ring (3) from
drive plate (2). Remove and discard
upper seal (1).
(d). Torque nuts (15) again in sequence, 1
B. Main Rotor Drive Shaft Upper Seal
thru 10, to 230 to 250 in-lb (25.99 Installation
to 28.25 Nm) plus (+) locking
torque. (Ref. Figure 402)
(1). Install upper seal (1) in main rotor
drive plate (2). Install spiral ring (3).
NOTE: Make sure the lip of the upper seal is
facing drive plate splines.
(2). Install main rotor drive plate (ref.
Procedure 2.B.).
(7). Apply sealing compound (C211) to bolt

heads, washers, and nuts (ref. CSP-
SPM).
(8). Apply sealing compound (C211) to form

a fillet seal on the mating edges of the
drive plate and upper hub (ref. CSP-
SPM). 2
1
(9). Seal all unpainted surfaces of the upper

hub (ref. CSP-SPM).
3
(10). Install the main rotor drive shaft.
9G63-003
1. UPPER SEAL, MAIN ROTOR HEAD (REF. IPL,
(11). Refer to Section 05-20-10, Table 203, 620000, FIG. 2)
Special Inspection - After Component 2. MAIN ROTOR DRIVE PLATE
Installation, Main Rotor Drive Plate 3. SPIRAL RETAINING RING
Nut Torque Verification, for more Figure 402. Main Rotor Drive Shaft Upper
maintenance. Seal
Page 404
Page 405
4
(4 PL)
3
(4 PL)
9G63-004A
1. TRANSMISSION SEAL (REF. IPL, 620000, FIG. 2) 4. WASHER
2. STATIC MAST BASE 5. ORING
3. BOLT 6. LOWER SEAL
Figure 403. Main Rotor Drive Shaft Lower Seal
4. Main Rotor Drive Shaft Lower Seal (a). Discard lower seal (6).
A. Main Rotor Drive Shaft Lower Seal B. Main Rotor Drive Shaft Lower Seal
Removal Installation
(Ref. Figure 403)
(Ref. Figure 403)
(1). Remove main transmission (ref. Section Consumable Materials
63-20-00). (Ref. CSPSPM)
Item Nomenclature
(2). Remove sealant from bolts (3).
(3). Remove bolts (3) and washers (4) from C205 Sealing Compound
transmission seal (1). C211 Sealing Compound, Corrosion Inhibitive
(4). Remove transmission seal (1) from
static mast base (2). (1). Install lower seal (6) in transmission
seal (1).
(5). Remove O-ring (5).
(a). Discard O-ring (5).
If serviceable, the transmission
CAUTION seal can be reused. Use care
during removal of the lower seal to prevent (2). Lubricate new O-ring (5) with lubricat
damage to the transmission seal. ing oil (C106).
(6). Remove lower seal (6) from transmis (3). Install O-ring (5) on transmission seal
sion seal (1). (1).
Page 406
(4). Install transmission seal (1) on static (a). Torque bolts (3) 36 to 46 in-lb (4.07
mast base (2). to 5.20 Nm).
Sealing Compound (C205) Sealing Compound (C211)
(5). Apply sealing compound (C205) to bolts (7). Seal bolts (3) with sealing compound
(3). (C211) (ref. CSP-SPM, 20-50-00,
Mechanical Fastener Sealing).
(6). With sealing compound (C205) still wet,
install transmission seal (1) with bolts (8). Install main transmission (ref. Section
(3) and washers (4). 63-20-00).
Page 407
5
3
1
2
(4 PL)
2
(4 PL)
9G63-002A
1. DRIVE SHAFT(REF. IPL, 631000, FIG. 1) 3. TRANSMISSION FLANGE

2. BOLT 4. ENGINE FLANGE
Figure 404. Removal and Installation of the Input Drive Shaft Assemblies
5. Input Drive Shaft Assemblies B. Drive Shaft Installation
(Ref. Figure 404)
A. Drive Shaft Removal
CAUTION
(Ref. Figure 404)
The drive shaft has a very thin wall thick
NOTE: This task is typical for left or right drive ness. Try to not touch other parts during
shaft removal. installation of the drive shaft. Damage
can cause an unbalanced drive shaft.
(1). Open Access Panel L210 and/or Access Axial displacement can cause too much oil
Panel R210 (ref. Section 06-00-00). leakage from the input pinion assembly.
If you think there is a misalignment dur
The drive shaft has a very thin ing the installation procedure, do the En
CAUTION wall thickness. Try to not touch gine to Transmission Alignment proce
other parts during removal of the drive dure (ref. Section 71-00-00,
shaft. Damage can cause an unbalanced Inspection/Test).
drive shaft.
NOTE: This task is typical for left or right drive
shaft installation.
(2). Remove bolts (2) from transmission
flange (3). (1). If a new drive shaft or new input pinion
assembly components are to be
(3). Remove bolts (2) from engine flange (4). installed, do the Engine to Transmis
sion Alignment procedure (ref. Section
71-00-00, Inspection/Test).
(4). Carefully remove drive shaft (1) from
transmission flange (3) and engine (2). Close Access Panel L210 and/or Access
flange (4). Panel R210 (ref. Section 06-00-00).
Page 408
(3). Carefully install drive shaft (1) between (4). Install bolts (2) in transmission flange
transmission flange (3) and engine (3).
flange (4).
(5). Install bolts (2) in engine flange (4).
NOTE: Correct alignment provides zero to posi (6). Torque bolts (2) 70 to 90 in-lb (7.91 to
tive clearance between the flanges to install 10.17 Nm) more than the locking
the drive shaft in tension. torque.
Page 409
2 (4 PL)
4
3 1
2 (4 PL) 1
9G63-027
1. FAN DRIVE SHAFT (REF. IPL, 631000, FIG. 2) 3. TRANSMISSION FLANGE
2. BOLT 4. ANTITORQUE COUPLING
Figure 405. Removal and Installation of NOTARr Fan Drive Shaft Assembly
6. NOTARr Fan Drive Shaft Assembly
CAUTION
A. Fan Drive Shaft Removal The fan drive shaft has very thin wall
thickness. Avoid contact with other parts
during removal of the fan drive shaft.
(Ref. Figure 405) Damage can cause an unbalanced fan
drive shaft.
Do not remove couplings from fan drive
(1). Remove access panels L210 and R210
shaft. Removal of couplings can cause an
unbalanced fan drive shaft (this does not
refer to the anti-torque fan shaft cou
(2). Remove Access Panel T220 (ref. Section pling).
53-30-00). (6). Remove bolts (2) from both ends of fan
drive shaft (1).
(3). Remove the electrical load center (7). Carefully remove fan drive shaft (1).
assembly (ref. Section 96-00-00).
B. Fan Drive Shaft Installation
(4). Remove the anti-torque fan forward (Ref. Figure 405)
duct assembly F1, F2, and F3 (ref.
Section 53-30-00). Consumable Materials
(Ref. CSPSPM)
(5). Remove the upper inlet duct cover from Item Nomenclature
the forward duct assembly (ref. Section C231 Releasing Agent
53-30-00).
Page 410
The fan drive shaft has a very Releasing Agent (C231)

CAUTION thin wall thickness. Try to not
touch other parts during installation of the
fan drive shaft. Damage can cause an un
balanced fan drive shaft.
(2). Wet install bolts (2) with releasing
agent (C231).
(1). Carefully install fan drive shaft (1)
between transmission flange (3) and (a). Make sure there is no releasing
anti-torque coupling (4). agent (C231) on the threads of bolts
(2) before installation.
(a). Measure the gap between fan drive (b). Torque bolts (2) 70 to 90 in-lb (7.91
shaft (1) and anti-torque fan cou to 10.17 Nm) more than the locking
pling (4). torque.
(3). Install the upper inlet duct cover on the
forward duct assembly (ref. Section
1). The gap must be 0.001 to 0.010 53-30-00).
inch (0.03 to 0.25 mm).
(4). Install the anti-torque fan forward
duct assembly F1, F2, and F3 (ref.
2). If the gap is more than 0.010 inch Section 53-30-00).
(0.25 mm), refer to the anti-
torque fan support installation (ref. (5). Install the electrical load center
Section 64-30-00). assembly (ref. Section 96-00-00).
(6). Install Access Panel T220 (ref. Section
53-30-00).
3). Make sure the minimum running
torque of the nutplates is 3.5 in-lb (7). Install access panels L210 and R210
(0.40 Nm) before bolt installation. (ref. Section 53-30-00).
Page 411
Page 412
DRIVE SHAFTS / CLUTCHES / COUPLINGS

INSPECTION / TEST
1. Input Drive Shaft Inspection (b). Dents that blend smoothly into
adjacent surface area with no sharp
change in contour and are not more
CAUTION than 0.015 inch (0.38 mm) deep and
1.000 inch (25.40 mm) long are
The input drive shaft is a high speed, permitted.
highly stressed, dynamically balanced
unit, subject to failure from damage, han (c). Nicks and scratches less than 0.005
dling or improper maintenance. It should inch (0.13 mm) deep and 1.000
be treated like any other fine precision inch (25.40 mm) long can be
aircraft component and handled in accor blended out.
dance with the procedures outlined.
(d). If there is a dent, nick, or scratch
An input drive shaft that is subjected to more than the specified limits,
conditions other than normal operation replace the input drive shaft.
conditions, such as, but not limited to sud
den stoppage, fire, flood, gearbox failure, (3). Inspect center tube for evidence of
hard landing, excessive misalignment, deformation.
vibration, etc., must be thoroughly in (a). If there is deformation, replace the
spected and/or replaced. input drive shaft.
The inspection procedures called out in B. Flanges
this document are critical. Therefore, it is
mandatory that the requirements for in (Ref. Figure 601)
put drive shaft replacement be strictly
adhered to. (1). Inspect the flange of shaft for cracks or
fretting.
A. Center Tube (a). If there are cracks or fretting, replace
the input drive shaft.
(Ref. Figure 601)
(2). Inspect the flange of shaft for corrosion.
NOTE: When you look at damage, careful dis (a). Corrosion less than 0.006 inch (0.15
tinction must be made between the base mm) deep which can be polished out
metal and the brown-colored primer. is permitted.
(b). If the corrosion is deeper than 0.006
(1). Inspect center tube for dents, nicks, or inch (0.15 mm), replace the input
scratches. drive shaft.
(2). Measure the depth and diameter of all (c). If the corrosion marks are deeper
dents, nicks, and scratches. than 0.006 inch (0.15 mm) replace
input drive shaft.
(a). A dent, nick, or scratch that is deeper C. Mounting Bolts
than 0.005 inch (0.13 mm) and
longer than 1.00 inch (25.4 mm) in (1). Do a torque check on the mounting
length is not permitted. bolts.
Page 601
No nicks, dents, or scratches on

outer rim greater than 0.015 IN
(0.381 mm) depth and 1.00 IN
(25.4 mm) length permitted.
center tube greater than 0.005 IN
(0.127mm) depth and 1.00 IN
No nicks, dents, scratches

into base metal permitted in
this area of diaphragm.
No corrosion on flange faces at a

depth greater than 0.006 IN
(0.1524 mm) permitted.
9g63-042-3
Figure 601. Input Drive Shaft Inspection
NO NICKS, DENTS
OR SCRATCHES
PERMITTED IN
BASE METAL IN
THIS AREA PROFILE AREA
NICKS AND
SCRATCHES
PERMITTED
IN BASE
METAL IN
THIS AREA 9g63-042-1
Figure 602. Diaphragm Inspection Areas
Page 602
(b). If there are dents in the profile area,

CAUTION replace the input drive shaft.
Do not scratch, mar, dent diaphragm pro (3). Externally inspect diaphragm profile
files. To do so can cause potential opera paint for crazed lines.
tional failure, loss of torque, and damage
to adjacent components and aircraft. (a). If there are crazed lines, reject and
replace the input drive shaft.
D. Diaphragms
NOTE: This is an indication that the input
(Ref. Figure 602) drive shaft has seen an over-angle or over
torque condition.
NOTE: When you look at damage, careful dis
tinction must be made between the base (4). Externally inspect the outer rim for
metal and the silver-colored primer (Serme nicks or scratches (ref. Figure 601).
tal).
(a). Nicks or scratches on the outer rim
(1). Externally inspect diaphragms for nicks less than 0.015 inch (0.38 mm) deep
or scratches. and 1.00 inch (25.40 mm) long,
which can be polished out are per
(a). Use 10X magnification to determine mitted.
if scratches have penetrated into the
base material. (b). if the nicks or scratches on the outer
rim are deeper than 0.015 inch (0.38
(b). If there are nicks or scratches that mm) and longer than 1.00 inch
have penetrated into the base (25.40 mm), replace the input drive
material in the diaphragm profile shaft.
area, replace the input drive shaft
(5). Examine the diaphragm surfaces for
(2). Externally inspect diaphragms for corrosion.
dents.
(a). If there is corrosion, replace the input
(a). No dents are permitted. drive shaft.
Page 603

outer rim greater than 0.010 IN No nicks, dents, or scratches on
(0.254 mm) depth and 1.00 IN center tube greater than 0.005 IN
(25.4 mm) length permitted. (0.127 mm) depth and 1.00 IN
No nicks, dents, scratches into

base metal permitted in this area of
No corrosion on flange faces at
diaphragm.
a depth greater than 0.006 IN
(0.1524 mm) permitted.
9g63-042-2
Figure 603. Inspection of NOTARR Fan Drive Shaft Assembly

2. NOTARR Fan Drive Shaft Assembly 3). Nicks and scratches less than
Inspection 0.005 inch (0.13 mm) deep and
1.000 inch (25.40 mm) long can
A. Center Tube be blended out (ref. Repairs).
(Ref. Figure 603) (2). Inspect center tube for evidence of
deformation.
tinction must be made between the base (a). If there is deformation, replace the
metal and the brown-colored primer. drive shaft.
(1). Inspect center tube for dents, nicks, or B. Diaphragms

scratches.
(a). Measure the depth and diameter of tinction must be made between the base
all dents, nicks, and scratches. metal and the silver-colored primer (Serme
tal).
1). If there is a dent, nick, or scratch
that is deeper than 0.005 inch (1). Externally inspect diaphragms for nicks
(0.13 mm) and longer than 1.000 or scratches.
inch (25.40 mm) in length,
replace the shaft assembly. (a). Nicks or scratches that have pene
trated into the base material in the
2). Dents that blend smoothly into diaphragm profile area shall require
surrounding surface area with no the input drive shaft replacement.
sharp change in contour and are Refer to Figure 602 for profile
not more than 0.010 inch (0.254 location. Use 10X magnification to
mm) deep and 1.000 inch (25.40 determine if scratches have pene
mm) long are permitted. trated into the base material.
Page 604
(2). Externally inspect diaphragms for 3. Main Rotor Drive Shaft Inspection
dents. None permitted.
A. Drive Shaft
(a). Dents found in the profile area
(Figure 602) shall require anti- (1). Wipe off all grease.
torque drive shaft replacement.
(2). Inspect all surfaces of drive shaft for
(3). Externally inspect diaphragm profile dents, nicks, scratches and evidence of
paint for crazed lines. Ref. Figure 602. deformation.
(a). If crazed lines are found, input drive (a). No damage of any kind is permitted
shaft is to be rejected and replaced in the area within 2.000 inch (50.80
(ref. Section 63-10-00). This is an mm) of the spline. No cracks are
indication that the input drive shaft allowed.
has seen over angle or torque condi
(b). Nicks, scratches and dents not
tion.
exceeding 0.004 inch (0.10 mm) in
(4). Externally inspect outer rim for nicks depth and 1.000 inch (25.40 mm) in
and scratches. Refer to Figure 603. length are permitted if polished out.
(a). Nicks and scratches on the outer rim (3). Inspect all external surfaces of shaft for
up to 0.010 inch (0.25 mm) in depth corrosion.
and 1.000 inch (25.40 mm) in
length which can be polished out are
NOTE: Spline surfaces will normally display a
permitted. wear pattern (discoloration or removal of sil
ver plating), however, pitting, spalling, or
(b). Nicks and scratches on the outer rim heavy grooved wear marks over more than
deeper than 0.0100 inch (0.25 mm) 50 percent of the wear area is not permitted.
and longer than 1.000 inch (25.40
mm) in length are not permitted. (4). Inspect splines on both ends of drive
Replace input drive shaft. shaft for excessive wear by measuring
distance across two 0.142 inch (3.61
(5). Inspect diaphragm surface for corro mm) diameter pins placed in opposite
sion. Shafts with traces of corrosion on spline grooves.
this area must be discarded.
NOTE: Measurements are to be taken over the
C. Flanges two pins, at a four places (minimum),
approximately 45 degrees apart, and aver
(1). Inspect flange faces of shaft for cracks, aged. When taking these measurements,
corrosion and fretting. No cracks
the pins must be carefully placed at the face
allowed.
width mid-point of the spline. The resulting
(a). Corrosion up to 0.006 in. (0.152 mm) value must be greater than or equal to the
in depth which can be polished out minimum value specified.
are permitted. Ref. Figure 603.
(a). For the upper spline, the dimension
(b). Corrosion deeper than 0.006 inch must be 4.4811 inch (113.820 mm)
(0.15 mm) is not permitted. Replace minimum.
input drive shaft.
(b). For the lower spline, the dimension
(c). If fretting marks are deeper than must be 3.6588 inch (92.934 mm)
0.006 inch (0.15 mm) replace input minimum.
drive shaft.
(5). If you are not sure of the shaft condi
D. Mounting Bolts tion, do a magnetic particle inspection
(ref. CSP-SPM, Section 20-90-00, Part
Inspect mounting bolts for torque. E.).
Page 605
4. Main Rotor Drive Plate Inspection NOTE:

Spline surfaces will normally display a
wear pattern (discoloration or removal of
A. Drive Plate silver plating). However, pitting, spalling,
or heavy grooved wear marks over more
than 50 percent of the wear area is not
(1). Wipe off all grease. permitted.
Measurements are to be taken between
the two pins, at a four places (minimum),
(2). Before removal, inspect the main rotor
approximately 45 degrees apart, and av
drive shaft cover and drive plate eraged. Resulting value must be less than
attaching hardware for evidence of or equal to the maximum value specified.
movement or looseness.
(5). Inspect splines for excessive wear by
measuring distance across two 0.142
(3). Inspect drive plate gear teeth for inch (3.63 mm) diameter pins placed
cracks, chips, or missing teeth. No in opposite spline grooves. The dimen
damage is permitted. sion must be 4.1459 inch (105.306
mm) maximum.
(6). If you are not sure of the drive plate
(4). Nicks, scratches, and dents not more condition, do a magnetic particle
than 0.004 inch (0.10 mm) deep can inspection (ref. CSP-SPM, Section
be polished out. 20-90-00, Part E.).
SURFACE X DIMENSION 1
SURFACE Y
SURFACE Z
CORROSION PIT DEPTH DIMENSION 3
DIMENSION 2
9G63-057
DIM. 1 DIM. 3
DIM. 2 DIM. 2
= DIM. 4 = DIM. 5
Figure 604. Drive Plate Pitting Inspection Areas
Page 606
B. Drive Plate Pitting 2). If Dimension 4 is more than or

equal to 2.108 inch (53.54 mm),
(Ref. Figure 604) subtract Dimension 2 from
(1). Inspect the mating surface of the drive Dimension 3 and record the
plate to upper hub assembly for result as Dimension 5.
corrosion and fretting pits. 3). If Dimension 5 is more than or
(2). If there is corrosion or fretting pits, do equal to 0.191 inch (4.85 mm), do
these steps: the Drive Plate Pitting Repair.
(a). Measure the distance from Surface (3). After completion of a Drive Plate
X to Surface Z and record value as Pitting Repair, do these steps:
Dimension 1.
(a). Measure the distance from Surface
(b). Measure the depth of corrosion/fret X to Surface Z.
ting pits and record the value as
Dimension 2. 1). The dimension must be more than
or equal to 2.107 inch (53.52
(c). Measure distance from Surface Y to mm).
Surface Z, and record the value as
Dimension 3. (b). Measure the distance from Surface
Y to Surface Z.
(d). If Dimension 1 is more than or
equal to 2.109 inch (53.66 mm), do 1). The dimension must be more than
these steps: or equal to 0.190 inch (4.83 mm).
1). Subtract Dimension 2 from (c). If the dimensions do not satisfy the
Dimension 1, and record the result requirements, contact a MDHI Field
as Dimension 4. Representative.
Page 607
(NOTE 1)
VIEW LOOKING DOWN AT TOP

8 OF MAIN ROTOR UPPER HUB
1 WITH DRIVE PLATE REMOVED
3
6
10
9
5
4 2
7
MAIN ROTOR DRIVE PLATE ATTACH

BOLTS AND NUTS (10 PL)
(NOTE 2)
NOTE:
1. MAIN ROTOR DRIVE PLATE ATTACHMENT HARDWARE TORQUE SEQUENCE.
2. TORQUE NUTS TO 230 - 250 IN-LB (25.98 - 28.25 Nm) PLUS (+) LOCKING TORQUE. 9G63-036
Figure 605. Main Rotor Drive Plate Nut Torque Sequence

5. Main Rotor Drive Plate Nut Torque Check NOTE:
Do not loosen a nut to determine the lock
ing (run-on) torque.
A. Procedure
The minimum torque is determined by
adding the locking (run-on) torque re
(Ref. Figure 605) corded in the Rotorcraft Log Book plus
(+) 230 in-lb (25.98 Nm)
(1). Make sure the torque strip is not
Consumable Materials broken on the upper hub assembly, and
(Ref. CSPSPM) the ten main rotor drive plate nuts and
Item Nomenclature bolts.
C211 Sealing Compound, Corrosion Inhibitive (a). Record results in the Rotorcraft Log
Book.
Page 608
(2). Remove sealant from bolts and nuts (if Sealing Compound (C211)
applicable).
(3). Make sure the main rotor drive plate

nuts are above the minimum torque. (5). Once no loss of torque is verified, apply
fillet seal to bolt heads and nuts with
(a). Torque check nuts to 225 in-lb SPM, Section 20-50-00, Environmen
(25.42 Nm). tal Sealing Methods).
(6). Apply torque stripe to the nuts, bolts,
(b). Record the position of all nuts that and upper hub assembly (ref. CSP-
moved in the Rotorcraft Log Book. SPM, Section 20-10-00, Identification
Stripe).
(4). Torque nuts in sequence, 1 thru 10, to NOTE: Ref. CSP-900RMM-2, Section
230 to 250 in-lb (25.98 to 28.25 Nm) 05-20-10, Table 203, Special Inspection -
plus (+) the locking (run-on) torque After Component Installation, Main Rotor
(ref. CSP-SPM, Section 20-10-00, Drive Plate Nut Torque Check, for addition
Torque Wrenches). al inspection requirements.
Page 609
Page 610
DRIVE SHAFTS / CLUTCHES / COUPLINGS

REPAIRS
1. Diaphragm Input Shaft Assembly Repairs Primer, Heresite (C312)
A. Blend Repair
Consumable Materials (4). Apply heresite primer (C312) to primed

(Ref. CSPSPM) area of shaft.
Item Nomenclature
(a). Let heresite primer (C312) dry for 1
C311 Primer, Heresite hour minimum at 203F (95C).
C312 Primer, Heresite 2. Diaphragm NOTARr Drive Assembly
C423 Solvent, Cleaning Repairs
C804 Abrasive Cloth A. Blend Repair
(1). Blend damaged area no deeper than
(Ref. CSPSPM)
0.015 inch (0.38 mm) with abrasive
Item Nomenclature
cloth (C804) to completely remove
damage. C311 Primer, Heresite
C312 Primer, Heresite
(a). Maintain a smooth transition into C423 Solvent, Cleaning
surrounding undamaged surface. C804 Abrasive Cloth
(b). Total rework area cannot have more (1). Blend damaged area no deeper than
than 4 reworks on center of tube. 0.010 inch (0.25 mm) with abrasive
Solvent, Cleaning (C423) damage.
(a). Maintain a smooth transition into
surrounding undamaged surface.
(b). Total rework area cannot have more
than 4 reworks on center of tube.
(2). Clean shaft with cleaning solvent Solvent, Cleaning (C423)
(C423).
Primer, Heresite (C311)
(2). Clean shaft with cleaning solvent

(C423).
Primer, Heresite (C311)
(3). Apply heresite primer (C311) to
abraded area of shaft.
(a). Let heresite primer (C311) dry for 1 (3). Apply heresite primer (C311) to
hour minimum at 203F (95C). abraded area of shaft.
Page 801
(a). Let heresite primer (C311) dry for 1 (1). Blend damaged area no deeper than
hour minimum at 203F (95C). 0.004 inch (0.10 mm) with abrasive
Primer, Heresite (C312) damage.
(a). Total blended area cannot be more

than 25 percent on the circumference
at any point.
(4). Apply heresite primer (C312) to primed
area of shaft. Solvent, Cleaning (C423)
(a). Let heresite primer (C312) dry for 1
hour minimum at 203F (95C).
3. Main Rotor Drive Shaft Repairs

(2). Clean shaft with cleaning solvent
A. Blend Repair (C423).
Consumable Materials Primer (C309)

(Ref. CSPSPM)
Item Nomenclature
C309 Primer
C804 Abrasive Cloth (3). Apply two coats of primer (C309) to the
area of repair.
.005 A
MATING SURFACE
FILLET
-A- RADIUS
9G63-056
Figure 801. Drive Plate Pitting Repair
Page 802
4. Main Rotor Drive Plate Repairs (a). Machine the surface 0.001 inch
(0.03 mm) past depth required to
A. Pitting Repair remove all corrosion and fretting pits.
(b). The surface finish must be 32 RMS.
(Ref. Figure 801)
(c). The fillet radius must be 0.005 to
0.015 inch (0.13 to 0.38 mm).
(Ref. CSPSPM) (d). The mating surface must be perpen
Item Nomenclature dicular to the centerline of Base A
Commercial Plating, Cadmium (BrushOn) within 0.005 inch (0.13 mm).
QQP416, Type II, CL 2 (2). Do a magnetic particle inspection (ref.
CSP-SPM, Section 20-90-00, Part E.).
(1). Machine mating surface of drive plate (3). Brush cadmium plate with a certified
to upper hub assembly to satisfy the low embrittlement solution to machined
following requirements: surface of drive plate.
Page 803
Page 804
Section
632000
Gearboxes
GEARBOXES
1. Main Transmission Assembly (g). Detach lateral vibration sensor
connector P431 (21).
A. Transmission Removal
NOTE: Residual oil could remain in oil lines
(Ref. Figure 402) and heat exchanger assemblies. When re
moving oil lines or components, take precau
Special Tools tions to catch oil with rags or a suitable con
(Ref. CSPSPM) tainer.
Item Nomenclature
T301 Transmission Removal Kit CAUTION
T3011 Dolly Assembly
T3012 Tray Assembly (8). Remove lockwire from left and right
hand oil out hoses (1). Remove left and
T3013 Pin
right hand oil out hoses (1). Drain
residual oil.
(1). Remove forward access door assembly
(9). Remove lockwire from left and right
L155 and R155 (Ref. Section hand oil in hoses (4). Remove left and
53-30-00). right hand oil in hoses (4). Drain
(2). Remove swashplate forward fairing residual oil.
(10). Remove right hand heat exchanger
(3). Remove transmission access door assembly (Ref. Section 63-21-00).
assembly L210 and R210 (Ref. Section Drain residual oil.
53-30-00).
(11). Drain residual oil from left hand heat
(4). Remove swashplate aft fairing assem exchanger (Ref. Section 63-21-00).
bly T220 (Ref. Section 53-30-00). (12). Remove left hand cooling interconnect
(5). Drain transmission oil (Ref. Section duct (4, Figure 404, Ref. Section
12-00-00). 63-21-00).
(6). Remove main rotor drive shaft (Ref. (13). Remove hydraulic pumps (Ref. Section
Section 63-10-00). 29-00-00). Leave hydraulic lines
connected.
(7). Detach connectors.
(14). Remove No.2 hydraulic manifold/reser
(a). Detach pressure transducer connec voir (Ref. Section 29-00-00).
tor P411 (3, Ref. Figure 408).
(15). Remove oil filler assembly (Ref. Section
(b). Detach temperature probe and 63-21-00).
switch connector P412 (11).
(16). Remove left and right hand input drive
(c). Detach pressure switch connector shaft (Ref. Section 63-10-00).
P413 (14).
(17). Remove NOTAR anti-torque drive
(d). Detach chip detector connector P415 shaft (Ref. Section 63-10-00).
(17).
(18). Disconnect and remove rotor brake
(e). Detach speed pickup connector P417 hydraulic line if applicable (Ref. Section
(6). 63-22-00). Leave clamps and brackets
attached to line.
(f). Detach vertical vibration sensor
connector P432 (10, Ref. Figure 402). (19). Remove drain pans.
Page 401
63-20-00 Original
(20). Install transmission removal kit (T301) (22). Cut and discard lockwire and remove
(Ref. Figure 401). tension bolts (17), countersunk washers
(16) and bolt isolators (15) from mast
(a). Position tray assembly (T301-2) (1) base.
under main transmission assembly.
(23). Raise ball caster jackscrews (4, Ref.
(b). Remove quick release pins (T301-3) Figure 401) until clearance is obtained
(2) and separate dolly assembly between transmission and mast base.
(T301-1) (3) sections. (24). Remove right hand mid-forward truss
and mid-aft truss mast base support
(c). Place dolly assembly (T301-1)
strut assemblies (Ref. Section
sections under transmission and
63-30-00).
connect sections with quick release
pins (T301-3). (25). Rotate transmission as necessary to
clear blockages and slide transmission
(d). Lower ball caster jackscrews (4) at to end of tray.
each corner of dolly assembly
(T301-1) until dolly meets bottom of NOTE: If replacing main transmission with
transmission assembly. like new item, perform the following steps.
(21). Remove bolt (18, Ref. Figure 402) and (26). Remove segmented isolators (11, Ref.
washer (19) and disconnect bonding Figure 402) from transmission.
jumper (20) from transmission. (27). Remove unions (2) and discard O-rings
(3).
(28). Remove unions (5) and discard O-rings
(6).
(29). Remove rotor brake head assembly and
disk if applicable (Ref. Section
63-22-00).
(30). Remove drain tubes.
1 (31). Remove left and right hand blower
impeller and blower housing assembly
3 (Ref. Section 63-21-00).
(32). Cut and discard lockwire and remove
vibration sensor (9) from velocimeter
bracket (8).
2 (33). Remove velocimeter bracket (8).
(a). Remove sealing compound from bolts
(7).
(b). Remove bolts and velocimeter
bracket.
(34). Remove carrier seal cover (12).
4
9G63-033
(a). Remove sealing compound from
1. TRAY ASSEMBLY (T3012) screws (14).
2. PIN (T3013)
3. DOLLY ASSEMBLY (T3011) (b). Cut and discard lockwire.
4. BALL CASTER JACKSCREW
(c). Remove screws (14), washers (13)
Figure 401. Transmission Tool and carrier seal cover (12).
Page 402
(35). Do the main rotor driveshaft inspection. Lubricant, Solid Film (C101)
B. Transmission Installation
(Ref. Figure 402)

(a). Spray threads of bolts (7) with solid
(Ref. CSPSPM) (b). Remove sealing compound from
Item Nomenclature upper two existing bolts in left hand
input pinion assembly.
C702 Lockwire
(c). Remove upper two existing bolts in
order to replace with longer bolts (7)
C101 Lubricant, Solid Film to install velocimeter bracket (8).
C110 Grease, Synthetic
(d). Install velocimeter bracket (8) with
C106 Oil, Lubricating bolts (7). Torque bolts (7).
or
Special Tools
(Ref. CSPSPM)
Item Nomenclature (e). Using mechanical fastener sealing
T301 Transmission Removal Kit method (Ref. CSP-SPM), apply
sealing compound (C211) to heads of
T3011 Dolly Assembly bolts.
T3012 Tray Assembly
(3). Install vibration sensor (9).
T3013 Pin
(a). Install vibration sensor on velocime
ter bracket. Torque vibration sensor
NOTE: If replacing main transmission with (9).
like new item, perform following steps.
(b). Safety vibration sensor with lockwire
(C702).
(1). Install carrier seal cover.
(4). Install left and right hand blower
(a). Install carrier seal cover (12) with housing assemblies and blower impeller
screws (14) and washers (13). Torque (Ref. Section 63-21-00).
screws (14).
(5). Install drain tubes if removed.
(b). Safety screws with lockwire (C702). (6). Install rotor brake disk and head
assembly if removed (Ref. Section
Sealing Compound (C211) 63-22-00).
Grease, Synthetic (C110)
(c). Using mechanical fastener sealing

(7). Pack transmission spline area with
method (Ref. CSP-SPM), apply
synthetic grease (C110) to sufficiently
sealing compound (C211) to heads of
cover spline teeth.
screws (14).
(8). Install segmented isolators (11) on
(2). Install velocimeter bracket (8). transmission.
Page 403
25
150 -161 in-lb

17
16.94 - 18.18 Nm 8 PL
16
15
18
20
19
14
21 23 4 PL
13
12
11 (TYP) 22
24
25 -30 in-lb
2.8 - 3.8 Nm
8 7 (2 PL)
10
4 (2 PL)
6 5
2 PL
3
2 1 (2 PL)
2 PL
9G63-018B
Figure 402. Transmission Assembly
Page 404

1. OIL OUT HOSE 14. SCREW
2. UNION 15. BOLT ISOLATOR
3. ORING 16. COUNTERSUNK WASHER
4. OIL IN HOSE 17. BOLT
5. UNION 18. BOLT
6. ORING 19. WASHER
7. BOLT 20. BONDING JUMPER
8. VELOCIMETER BRACKET 21. CONNECTOR (P431)
9. VERTICAL VIBRATION SENSOR 22. SPRING
10. CONNECTOR (P432) 23. LATERAL VIBRATION SENSOR
11. SEGMENTED ISOLATOR 24. CARRIER SUPPORT LOCKWASHER
12. CARRIER SEAL COVER 25. MAIN ROTOR DRIVE SHAFT
13. WASHER
Oil, Lubricating (C122) Lubricant, Solid Film (C101)

(a). Spray threads of bolts (17, Ref.

Figure 402) with solid film lubricant
(C101).
Verify proper lubricating oil for
CAUTION transmission before starting (b). Install bolt isolators (15), counter
work. Do not mix different specification lu sunk washers (16) and bolts (17)
bricating oil, damage will result. (Ref. Sec through mast base assembly into
tion 12-00-00, Table 1) transmission. Torque bolts (17).
(c). Safety bolts with lockwire (C702).
(9). Lubricate new O-rings (3) with proper (16). Prepare surface for electrical bond (Ref.
lubricating oil and install on unions (2). CSP-SPM).
Install unions. Torque unions.
(17). Connect bonding jumper.
(10). Lubricate new O-rings (6) with proper
lubricating oil and install on unions (5).
Install unions (5). Torque unions (5).
(11). Ensure spring (22) and lockwasher (24) (a). Spray threads of bolt (18) with solid
are installed. film lubricant (C101).
(b). Connect bonding jumper (20) to
(12). Install transmission on dolly assembly transmission with washer (19) and
(T301-1) (1, Ref. Figure 401). bolt (18). Torque bolt (18).
(18). Remove main transmission removal kit
(13). Slide transmission on tray assembly (T301) (Ref. Figure 401).
(T301-2) (3) under mast base assembly (a). Raise ball caster jackscrews (4)
and orient correctly. completely at each corner of dolly
assembly (T301-1) (1).
(14). Lower ball caster jackscrews (4) at each (b). Remove quick release pins (T301-3)
corner of dolly assembly (T301-1) (1) (2) and separate dolly assembly
until transmission mates with mast (T301-1) sections.
base.
(c). Remove dolly assembly (T301-1) (1)
and tray assembly (3) from transmis
(15). Install bolt isolators. sion deck.
Page 405
(19). Install right hand mid-forward truss (b). Attach temperature probe and switch
and mid-aft truss mast base support connector P412 (11).
strut assemblies (Ref. Section
63-30-00). (c). Attach pressure switch connector
P413 (14).
(20). Install drip pans.
(d). Attach chip detector connector P415
(21). Install rotor brake hydraulic line if (17).
applicable (Ref. Section 63-22-00).
(e). Attach speed pickup connector P417
(22). Install anti-torque drive shaft (Ref.
(6).
Section 63-10-00).
(23). Check engine to transmission align (f). Attach vertical vibration sensor
ment and realign if necessary (Ref. connector P432 (10, Ref. Figure 402).
Section 71-00-00). (g). Attach lateral vibration sensor
(24). Install left and right hand input drive connector P431 (21) to vibration
shafts (Ref. Section 63-10-00). sensor (23).
(25). Install oil filler assembly (Ref. Section (35). Install main rotor drive shaft (Ref.
63-21-00). Section 63-10-00).
(26). Install hydraulic pumps (Ref. Section (36). Service transmission (Ref. Section
29-00-00). 12-00-00).
(27). Install No.2 hydraulic manifold/reser (37). Verify no leaks are present in flam
voir (Ref. Section 29-00-00). mable fluid systems, where mainten
(28). Install left hand cooling interconnect ance or replacement of components,
duct (4, Figure 404, Ref. Section lines, or fittings has occurred, by
63-21-00). application of system pressure and
(29). Install right hand heat exchanger being returned to service.
(38). Install swashplate aft fairing assembly
(30). Connect oil out hoses (1). Torque hoses T220 (Ref. Section 53-30-00).
(1).
(39). Install swashplate forward fairing
(31). Safety oil out hoses (1) with lockwire assembly T155 (Ref. Section 53-30-00).
(C702).
(40). Install transmission access door
(32). Connect oil in hoses (4). Torque hoses assembly L210 and R210 (Ref. Section
(4). 53-30-00).
(33). Safety oil in hoses (4) with lockwire
(41). Install forward access door assembly
(C702).
(34). Attach connectors. 53-30-00).
(a). Attach pressure transducer connector (42). Perform transmission operation test -
P411 (3, Ref. Figure 408). run-up (Ref. Section 63-20-00).
Page 406
2. Input Pinion Assembly B. Input Pinion Assembly Installation

(Ref. Figure 403)
NOTE: If helicopter is equipped with a
900D1400006-101 transmission, ensure Consumable Materials
original input pinion is retained with trans (Ref. CSPSPM)
mission. (Ref. Section 05-10-00, Table 201). Item Nomenclature
A. Input Pinion Assembly Removal or
C702 Lockwire
(Ref. Figure 403)
Special Tools
Special Tools
(Ref. CSPSPM)
(Ref. CSPSPM)
Item Nomenclature
Item Nomenclature
T304 Guide Pins
T304 Guide Pins T2004 Heat Gun
T306 Jackscrews
NOTE: This task is typical for left or right input
pinion installation.
NOTE: This task is typical for left or right input Oil, Lubricating (C122)
pinion removal. Oil, Lubricating (C106)
(1). Remove main transmission input drive

shaft assembly (Ref. Section 63-10-00).

(2). Cut and discard lockwire from flexible CAUTION transmission before starting
drain tubing. Disconnect tubing from work. Do not mix different specification lu
input pinion assembly. bricating oil, damage will result. (Ref. Sec
tion 12-00-00, Table 1)
(3). Remove sealing compound from bolts (1). Lubricate new O-ring (5) with proper
(3). Remove bolts (3) and washers (4). lubricating oil and install on input
pinion assembly (1).
(4). Remove sealing compound from (2). Using heat gun (T2004), heat cavity
surfaces of input pinion assembly (1) area of transmission (2) to not more
and main transmission assembly (2). than 200F (93.3C).
(3). Install guide pins (T304) in two top bolt
(5). Install guide pins (T304) in two top bolt holes.
holes. (4). Install input pinion assembly (1) in
main transmission assembly (2). Install
Main Housing may be damaged bolts (3) and washers (4) into bottom
CAUTION if guide pins are not used. holes.
(5). Remove guide pins and install bolts (3)
and washers (4). Torque bolts (3).
(6). Using jackscrews (T306), remove input
pinion assembly (1) from main trans (6). Verify that backlash exists. (Manually
mission assembly (2) and discard rotate input pinion backwards and
O-ring (5). forwards.)
Page 407
(7). Perform transmission operation test - (10). Using fillet surface sealing method (Ref.
manual rotation (Ref. Section CSP-SPM), apply sealing compound
63-20-00). (C205) to parting line of input pinion
assembly (1) and main transmission
(8). Connect flexible drain tubing to input assembly (2).
pinion assembly. Safety connection with (11). Install input drive shaft assembly (Ref.
lockwire (C702). Section 63-10-00).
Sealing Compound (C205) (12). Service transmission (Ref. Section

12-00-00).
(13). Verify no leaks are present in flam
mable fluid systems, where mainten
ance or replacement of components,
(9). Using mechanical fastener sealing application of system pressure and
method (Ref. CSP-SPM), apply sealing visual inspection prior to helicopter
compound (C205) to heads of bolts (3). being returned to service.
Page 408
REMOVAL
7
4
(8 PL)
2
62 -82 in-lb
3 7 - 9.2 Nm
(8 PL)
9G63-006A
1. INPUT PINION ASSEMBLY 5. ORING

2. MAIN TRANSMISSION ASSEMBLY 6. GUIDE PINS (T304)
3. BOLT 7. JACKSCREWS (T306)
4. WASHER
Figure 403. Input Pinion Assembly
Page 409
3. Fan Drive Assembly B. Fan Drive Assembly Installation

900D1400006-101 transmission, ensure
(Ref. CSPSPM)
original input pinion is retained with trans
Item Nomenclature
mission. (Ref. Section 05-10-00, Table 201).
(Ref. Figure 404) or
A. Fan Drive Assembly Removal
C702 Lockwire
(1). Remove anti-torque drive shaft C205 Sealing Compound
(2). Remove rotor brake disk (Ref. Section Oil, Lubricating (C122)
63-22-00). Oil, Lubricating (C106)
(3). Cut and discard lockwire from flexible

drain tubing. Disconnect tubing from
fan drive assembly.
(4). Remove sealing compound from bolts CAUTION transmission before starting
(3). Remove bolts (3) and washers (4). work. Do not mix different specification lu
(5). Remove sealing compound from bricating oil, damage will result. (Ref. Sec
surfaces of fan drive assembly (1) and tion 12-00-00, Table 1)
main transmission (2). (1). Lubricate new O-ring with proper
lubricating oil and install on fan drive
(6). Heat main transmission assembly assembly.
adjacent to the fan drive assembly to
not more than 200 F (93.3 C). (2). Heat main transmission assembly
adjacent to fan drive cavity to not more
(7). Remove fan drive assembly from main than 200 F (93.3 C).
transmission assembly and discard (3). Align fan drive assembly with main
O-ring (5). transmission and evenly push into
place by hand. Install bolts and
washers. Torque bolts.
(4). Verify that backlash exists. (Manually
rotate fan drive pinion backwards and
forwards.)
(5). Connect flexible drain tubing to fan
drive assembly. Safety connection with
lockwire (C702).
(6). Using mechanical fastener sealing

method (Ref. CSP-SPM), apply sealing
compound (C205) to heads of bolts.
(7). Using fillet surface sealing method (Ref.
CSP-SPM), apply sealing compound
(C205) to parting line of fan drive
assembly and main transmission.
Page 410
(8). Install rotor brake disk (Ref. Section 4. Lubrication Pump Drive Assembly
63-22-00).
(9). Service transmission (Ref. Section NOTE: If helicopter is equipped with a
12-00-00). 900D1400006-101 transmission, ensure
original input pinion is retained with trans
(10). Install anti-torque drive shaft mission. (Ref. Section 05-10-00, Table 201).
(11). Verify no leaks are present in flam A. Lubrication Pump Drive Assembly
mable fluid systems, where mainten Removal
lines, or fittings has occurred, by (Ref. Figure 405)
application of system pressure and
being returned to service. Special Tools
(Ref. CSPSPM)
Item Nomenclature
T306 Jackscrews
5
(1). Remove lubrication pump (Ref. Section
63-21-00).
NOTE: Residual oil could remain in oil lines.

When removing oil lines or components,
take precautions to catch oil with rags or a
1 suitable container.
4 (5 PL) 2
(2). Remove sealing compound from
3 62 -82 in-lb surfaces of lubrication pump drive
(5 PL) 7 - 9.2 Nm assembly (1) and main transmission
9G63-012
(2).
1. FAN DRIVE ASSEMBLY
2. MAIN TRANSMISSION
3. BOLT (3). Using jackscrews (T306) remove
4. WASHER lubrication pump drive assembly (1)
5. ORING
from main transmission (2) and discard
Figure 404. Fan Drive Assembly O-rings (3).
Page 411
B. Lubrication Pump Drive Assembly pump drive assembly (1) and main
Installation transmission (2).
(Ref. Figure 405) (4). Install lubrication pump (Ref. Section
63-21-00).
(Ref. CSPSPM)
Item Nomenclature
or
Oil, Lubricating (C122) 2

3

CAUTION transmission before starting
work. Do not mix different specification lu
bricating oil, damage will result. (Ref. Sec
tion 12-00-00, Table 1)
(1). Lubricate new O-rings (3) with proper
lubricating oil and install on lubrication
pump drive assembly (1).
(2). Align drive assembly with main
transmission (2) and evenly push into
place by hand.
4
1. LUBRICATION PUMP DRIVE ASSEMBLY

3. ORING
4. JACKSCREWS (T306)
CSP-SPM), apply sealing compound Figure 405. Lubrication Pump Drive
(C205) to parting line of lubrication Assembly
Page 412
5. Hydraulic Pump Accessory Drive B. Hydraulic Pump Accessory Drive

Assembly Assembly Installation
(Ref. Figure 406)
original input pinion is retained with trans Consumable Materials
mission. (Ref. Section 05-10-00, Table 201). (Ref. CSPSPM)
Item Nomenclature
A. Hydraulic Pump Accessory Drive C106 Oil, Lubricating
Assembly Removal or
(Ref. Figure 406) C702 Lockwire
Special Tools
(Ref. CSPSPM) NOTE: This task is typical for left or right hy
Item Nomenclature draulic pump accessory drive assembly
installation.
T344 Puller Assembly
NOTE: This task is typical for left or right hy

draulic pump accessory drive assembly re
moval.
(1). Remove hydraulic pump assembly (Ref. work. Do not mix different specification lu
Section 29-00-00). bricating oil, damage will result. (Ref. Sec
tion 12-00-00, Table 1)
(2). Cut and discard lockwire from flexible (1). Reassemble hydraulic pump accessory
drain tubing (3). Disconnect tubing drive assembly (1) if necessary
from drive assembly.
(a). Lubricate new O-ring (8) with proper
(3). Remove sealing compound from bolts lubricating oil and install on accesso
(4). Remove bolts (4) and washers (5). ry seal housing assembly (7).
(b). Align accessory seal housing assem
(4). Remove sealing compound from bly (7) with accessory bearing
surfaces of hydraulic pump accessory retainer assembly (9) and evenly
drive assembly (1) and main transmis push into place by hand.
sion (2).
(2). Lubricate new O-ring (6) with proper
lubricating oil and install on accessory
(5). Remove accessory seal housing assem bearing retainer assembly (9).
bly (7) from accessory bearing retainer
assembly (9), using puller assembly (3). Align hydraulic pump accessory drive
(T344). Discard O-ring (8). assembly (1) with main transmission
(2) and evenly push into place by hand.
(6). Remove accessory bearing retainer (4). Install bolts (4) and washers (5). Torque
assembly (9) from main transmission bolts (4).
(2). Screws with 1/4-20 UNC thread
may be installed in two jackscrew (5). Connect flexible drain tubing (3) to
thread holes. Discard O-ring (6). hydraulic pump accessory drive
Page 413
assembly (1). Safety connection with

lockwire (C702).
6
compound (C205) to heads of bolts (4).
(C205) to parting line of hydraulic 9
2
pump accessory drive assembly (1) and 8
1
main transmission (2). 7
(8). Install hydraulic pump assembly (Ref.

5 (4 PL)
Section 29-00-00).
4 70 -90 in-lb
(4 PL) 7.9 - 10.1 Nm
9G63-011A
1. HYDRAULIC PUMP ACCESSORY DRIVE
3. DRAIN TUBING
4. BOLT
5. WASHER
6. ORING
7. ACCESSORY SEAL HOUSING ASSEMBLY
8. ORING
9. ACCESSORY BEARING RETAINER ASSEMBLY
Figure 406. Hydraulic Pump Accessory Drive
Assembly
Page 414
6. Blower Drive Assembly (5). Remove blower drive assembly (1) from
main transmission (2) and discard
NOTE: If helicopter is equipped with a O-ring (5).
original input pinion is retained with trans B. Blower Drive Assembly Installation
mission. (Ref. Section 05-10-00, Table 201).
(Ref. Figure 407)
A. Blower Drive Assembly Removal

(Ref. CSPSPM)
NOTE: This task is typical for left or right blow Item Nomenclature
er drive assembly removal. C106 Oil, Lubricating
or
(1). Remove blower housing assembly (Ref.
Section 63-21-00). C122 Oil, Lubricating
C702 Lockwire
(2). Cut and discard lockwire from flexible C205 Sealing Compound
drain tubing. Disconnect tubing from
blower drive assembly.
NOTE: This task is typical for left or right blow
er drive assembly installation.


tion 12-00-00, Table 1)
1
80 -100 in-lb (1). Lubricate new O-ring (5) with proper
9.0 - 11.2 Nm
5
lubricating oil and install on blower
4 drive assembly (1).
(4 PL) 3
(4 PL)
(2). Install drive assembly in main trans
mission (2). Install nuts (3) and wash
2
9G63-010
ers (4). Torque nuts (3).
1. BLOWER DRIVE ASSEMBLY
(3). Connect flexible drain tubing to blower
2. MAIN TRANSMISSION ASSEMBLY
3. NUT drive assembly. Safety connection with
4. WASHER lockwire (C702).
5. ORING
Figure 407. Blower Drive Assembly
(3). Remove sealing compound from nuts

(3). Remove nuts (3) and washers (4).
(4). Remove sealing compound from (4). Using mechanical fastener sealing
surfaces of blower drive assembly (1) method (Ref. CSP-SPM), apply sealing
and main transmission (2). compound (C205) to nuts (3).
Page 415
(5). Using fillet surface sealing method (Ref. Oil, Lubricating (C122)
CSP-SPM), apply sealing compound Oil, Lubricating (C106)
(C205) to parting line of blower drive
assembly (1) and main transmission
(2).
(6). Service transmission (Ref. Section
12-00-00).
(7). Install blower housing assembly (Ref. CAUTION transmission before starting
Section 63-21-00). work. Do not mix different specification lu
(8). Verify no leaks are present in bricating oil, damage will result. (Ref. Sec
flammable fluid systems, where tion 12-00-00, Table 1)
maintenance or replacement of
components, lines, or fittings has (1). Lubricate new O-ring (4) and pressure
occurred, by application of system transducer (1) threads with proper
pressure and visual inspection prior to lubricating oil. Install O-ring on
helicopter being returned to service. pressure transducer.
7. Pressure Transducer
(2). Install and torque pressure transducer
A. Pressure Transducer Removal
(1). Safety transducer with lockwire
(Ref. Figure 408) (C712).
(1). Open transmission access door assem
bly L210 and R210 (Ref. Section Sealing Compound (C205)
06-00-00).
(2). Detach connector P411 (3) from
pressure transducer (1).
surfaces of pressure transducer (1) and (3). Using fillet surface sealing method (Ref.
main transmission (2). CSP-SPM), apply sealing compound
(C205) to parting line of pressure
(4). Cut and discard lockwire from trans transducer (1) and main transmission
ducer. Remove transducer from main (2).
transmission (2) and discard O-ring (4).
B. Pressure Transducer Installation (4). Verify no leaks are present in flam
(Ref. Figure 408) ance or replacement of components,
Consumable Materials application of system pressure and
(Ref. CSPSPM) visual inspection prior to helicopter
Item Nomenclature being returned to service.
or (5). Attach connector P411 (3).
C712 Lockwire (6). Close transmission access door assem
C205 Sealing Compound bly L210 and R210 (Ref. Section
06-00-00).
Page 416
8. Transmission Speed Pickup Oil, Lubricating (C122)

A. Transmission Speed Pickup Removal
(Ref. Figure 408)
(1). Open transmission access door assem Verify proper lubricating oil for
bly L210 and R210 (Ref. Section CAUTION transmission before starting
06-00-00). work. Do not mix different specification lu
(2). Detach connector P417 (6) from tion 12-00-00, Table 1)
transmission speed pickup (5).
(3). Remove sealing compound from bolts lubricating oil and install on transmis
(7). Remove bolts (7) and washers (8). sion speed pickup (5).
(4). Remove sealing compound from (3). Install speed pickup with bolts (7) and
surfaces of speed pickup (5) and main washers (8). Torque bolts (7).
transmission (2). Sealing Compound (C205)
(5). Remove speed pickup (5) and discard
O-ring (9).
B. Transmission Speed Pickup Installation

(Ref. Figure 408) method (Ref. CSP-SPM), apply sealing
compound (C205) to bolts (7).
Consumable Materials (5). Using fillet surface sealing method (Ref.

(Ref. CSPSPM) CSP-SPM), apply sealing compound
Item Nomenclature (C205) to parting line of pickup (5) and
main transmission (2).
or (6). Attach connector P417 (6).
C122 Oil, Lubricating (7). Verify no leaks are present in flam
C205 Sealing Compound mable fluid systems, where mainten
(1). Close transmission access door assem application of system pressure and
bly L210 and R210 (Ref. Section visual inspection prior to helicopter
06-00-00). being returned to service.
Page 417
9. Temperature Probe and Switch Oil, Lubricating (C122)

A. Temperature Probe and Switch Removal
(Ref. Figure 408)
(1). Open forward access door assembly Verify proper lubricating oil for
R155 (Ref. Section 06-00-00). CAUTION transmission before starting
(2). Open transmission access door assem bricating oil, damage will result. (Ref. Sec
bly R210 (Ref. Section 06-00-00). tion 12-00-00, Table 1)
(3). Drain oil from transmission (Ref. (1). Lubricate new O-ring (12) and temper
Section 12-00-00). ature probe and switch (10) threads
with proper lubricating oil. Install
NOTE: Residual oil could remain in oil lines. O-ring on temperature probe and
When removing oil lines or components, switch.
take precautions to catch oil in rags or a
suitable container. (2). Install and torque temperature probe
and switch (10). Safety temperature
(4). Detach connector P412 (11) from probe and switch with lockwire (C712).
temperature probe and switch (10). Sealing Compound (C205)
transmission housing (2), temperature
probe and switch (10).
(6). Cut and discard lockwire from tempera (3). Using fillet surface sealing method (Ref.
ture probe and switch (10). Remove CSP-SPM), apply sealing compound
temperature probe and switch (10) from (C205) to parting line of temperature
main transmission (2) and discard probe and switch (10) and main
O-ring (12). transmission (2).
(4). Attach connector P412 (11).
B. Temperature Probe and Switch
Installation (5). Service transmission (Ref. Section
12-00-00).
(Ref. Figure 408)
Consumable Materials ance or replacement of components,
(Ref. CSPSPM) lines, or fittings has occurred, by
Item Nomenclature application of system pressure and
C106 Oil, Lubricating visual inspection prior to helicopter
or
C122 Oil, Lubricating (7). Close forward access door assembly
C712 Lockwire R155 (Ref. Section 06-00-00).
C205 Sealing Compound (8). Close transmission access door assem
bly R210 (Ref. Section 06-00-00).
Page 418
70 -85 in-lb
7.9 - 9.6 Nm 4
1
3
5
6
2
12
8 (2 PL)
7
(2 PL)
32 -37 in-lb 11
3.6 - 9.1 Nm
VIEW ROTATED 10
70 -85 in-lb 70 -85 in-lb
15
7.9 - 9.6 Nm 7.9 - 9.6 Nm
13
14 20
70 -85 in-lb
19 7.9 - 9.6 Nm
18
16
17
9G63-013
1. PRESSURE TRANSDUCER 11. CONNECTOR (P412)

2. MAIN TRANSMISSION 12. ORING
3. CONNECTOR (P411) 13. PRESSURE SWITCH (LOW)
4. ORING 14. CONNECTOR (P413)
5. TRANSMISSION SPEED PICKUP 15. ORING
6. CONNECTOR (P417) 16. CHIP DETECTOR
7. BOLT 17. CONNECTOR (P415)
8. WASHER 18. ORING
9. ORING 19. CHIP DETECTOR SCREEN & VALVE ASSEMBLY
10. TEMPERATURE PROBE & SWITCH 20. ORING
Figure 408. Transmission Pressure Transducer, Speed Pickup, Chip Detector, Temperature
Probe & Switch and Pressure Switch
Page 419
10. Pressure Switch lubricating oil. Install O-ring on

pressure switch.
A. Pressure Switch (Low) Removal
(2). Install and torque pressure switch (13).
(Ref. Figure 408) Safety pressure switch with lockwire
(C712).
(1). Open forward access door assembly
L155 and R155 (Ref. Section Sealing Compound (C205)
06-00-00).
(2). Detach connector P413 (14) from

pressure switch.
pressure switch (13) and transmission
(C205) to parting line of pressure
housing (2).
switch (13) and main transmission (2).
(4). Cut and discard lockwire from pressure (4). Attach connector P413 (14).
switch (13).
(5). Remove pressure switch (13) from main mable fluid systems, where mainten
transmission (2) and discard O-ring ance or replacement of components,
(15). lines, or fittings has occurred, by
B. Pressure Switch (Low) Installation visual inspection prior to helicopter
(Ref. Figure 408)
(6). Close forward access door assembly
06-00-00).
(Ref. CSPSPM)
Item Nomenclature
11. Chip Detector
or A. Chip Detector Removal
(Ref. Figure 408)
C712 Lockwire
C205 Sealing Compound (1). Open transmission access door assem
bly L210 and R210 (Ref. Section
06-00-00).
Oil, Lubricating (C106) (2). Drain oil from transmission (Ref.
Section 12-00-00).
NOTE: Residual oil could remain in oil lines.

take precautions to catch oil in rags or a
Verify proper lubricating oil for suitable container.
work. Do not mix different specification lu (3). Detach connector P415 (17) from chip
bricating oil, damage will result. (Ref. Sec detector (16).
tion 12-00-00, Table 1)
(4). Push in and turn counterclockwise on
(1). Lubricate new O-ring (15) and pres chip detector (16) and pull out. Discard
sure switch (13) threads with proper O-ring (18).
Page 420
B. Chip Detector Installation lubricating oil and install on chip

detector (16).
(Ref. Figure 408)
(2). Push chip detector (16) into valve
Consumable Materials assembly (19) and turn clockwise to
(Ref. CSPSPM) lock in place.
Item Nomenclature
C106 Oil, Lubricating (3). Attach connector P415 (17).
or
12-00-00).
Oil, Lubricating (C106) (5). Verify no leaks are present in flam
mable fluid systems, where mainte
nance or replacement of components,
Verify proper lubricating oil for visual inspection prior to helicopter
CAUTION transmission before starting being returned to service.
bricating oil, damage will result. (Ref. Sec (6). Close transmission access door assem
tion 12-00-00, Table 1) bly L210 and R210 (Ref. Section
(1). Lubricate new O-ring (18) with proper 06-00-00).
Page 421
12. Chip Detector Screen and Valve (Housing) Oil, Lubricating (C122)
Assembly Oil, Lubricating (C106)
A. Screen and Valve (Housing) Assembly
Removal
(Ref. Figure 408)
(1). Remove chip detector (Ref Section
63-20-00). CAUTION transmission before starting
(2). Remove sealing compound from work. Do not mix different specification lu
transmission housing (2), chip detector bricating oil, damage will result. (Ref. Sec
screen and valve assembly (19). tion 12-00-00, Table 1)
(3). Cut and discard lockwire from chip
detector screen and valve assembly (1). Lubricate new O-ring (20) and chip
(19). detector screen and valve assembly (19)
threads with proper lubricating oil and
(4). Remove valve assembly from main install O-ring on valve assembly.
transmission (2) and discard O-ring
(20).
(2). Install and torque screen and valve
B. Screen and Valve (Housing) Assembly assembly (19). Safety valve assembly
Installation with lockwire (C712).
(Ref. Figure 408)
(Ref. CSPSPM)
Item Nomenclature
or
C122 Oil, Lubricating CSP-SPM), apply sealing compound
C712 Lockwire (C205) to parting line of screen and
C205 Sealing Compound valve assembly (19) and main transmis
sion (2).
Page 422
GEARBOXES
INSPECTION/TEST
1. Transmission Inspections (Area 3) must be less than 2cc in one hour or
one drop in one minute.
(Ref. Figure 601)
(4). Examine external surface of transmis
A. Transmission Inspection sion for damage and corrosion. None
permitted.
(1). Examine transmission for loose,
(5). Examine transmission for loose or
missing, and damaged bolts and nuts.
missing environmental seal at all
None permitted.
mating lines and on all bolts and nuts.
(2). Examine transmission shaft seals for (6). Examine all electrical connectors for
indication of oil leakage. Leakage rate correct installation and condition. No
at shaft seals must be less than 2cc in incorrect installation or unserviceable
one hour or one drop in one minute. condition permitted.
(3). Examine input pinions for indication of (7). Make sure transmission oil level is
leakage. Leakage rate at input pinions correct (Ref. Section 12-00-00).
Page 601
MATING LINE
ENVIRONMENTAL SEAL
9g63-065-1
Figure 601. Transmission Mating Line Environmental Seal (Sheet 1 of 3)
Page 602
9g63_065_2
Page 603
9g63_065_3
Page 604
B. Acoustic Isolator Inspection Bearings operators can not remove are made
of M50 or CBS-600 (Japanese equivalents).
(1). Examine acoustic isolator for too much M50 metal particles are from Planetary
elastomeric material out from between bearings and CBS-600 metal particles are
static mast support and transmission. from tapered roller bearings. If you get these
No damage permitted. metal particles, it is necessary to overhaul
transmission.
(2). Examine external surfaces of acoustic
isolator for cracks or delamination. No Other metals in transmission are 4340
damage permitted. clutches and 4130 lock nuts.
NOTE: Loose bolts can be an indication of wear
or deterioration of acoustic isolator. Metal particles can be found on chip detector
when transmission CHIPS caution message is
(3). Examine bolts that attach transmission shown on Integrated Instrument Display
to mast base for correct installation. No System (IIDS) or during usual maintenance. If
incorrect installation permitted. there are metal particles, it is not necessarily
an indication transmission is unserviceable.
C. Chip Detector Inspection But, the type and quantity of metal particles
found can be an indication there is a defective
NOTE: For more aid, speak to your local MDHI transmission component.
Field Service Representative.
(1). Remove chip detector and screen/valve
The components of the transmission are made (housing) assembly.
of different materials. You can find which
component(s) made the metal particles when (2). Examine chip detector and housing for
you have an Energy Dispersive X-ray Spec metal particles (Ref. Table 601).
troscopy, or equivalent test, done.
Operator removable bearings are made of (3). Make sure chip detector and housing
52100. These are the hydraulic pump, cooling are clean of all particles.
blower, notar, input, lube pump, and clutch
bearings. Some of these can be replaced (4). Install screen/valve (housing) assembly
without removal of the transmission. and chip detector.
Table 601. Metal Particle Inspection

Material Quantity/Size Probable Cause Corrective Action Ref. Section
Magnetic Fuzz or fine hairlike Result of normal wear. Clean off chip detector 632000
particles (one or two and housing and perform
particles) 0.02 x 0.14 chip detector test.
inches (.51 x 3.56 mm)
Inspect filter impending
long.
bypass (popup)
indicator
Multiple (heavy) deposits Impending failure of an Perform transmission 632000
of chips greater than internal component. serviceability test.
0.06 inch (1.52 mm) in
diameter.
Chips larger than Internal component Replace transmission. 632000
0.08 x 0.14 inches failure.
(2.03 x 3.56 mm)
Nonmagnetic Heavy deposits on May have resulted during Perform transmission 632000
nonmagnetic particles. assembly. serviceability test.
Page 605
2. Transmission Tests (h). Transmission high red oil C warning

segment is not illuminated.
A. Transmission Operational Test Runup
(i). Transmission CHIPS is not illumi
(1). On ELECTRICAL MASTER panel set nated.
POWER switch to BAT/EXT.
(j). Transmission FIRE is not illumi
(2). On IIDS secondary panel observe the nated.
following conditions:
(k). Check ROTOR BRAKE is not
(a). Transmission oil %PSI digital illuminated in caution/warning
display indicates 0%. cluster.
(3). Start and operate engine (left or right)
(b). Transmission low yellow %PSI
at FLY with main rotor blades in flat
caution segment is illuminated.
pitch per current Rotorcraft Flight
(c). Transmission high yellow %PSI Manual (Ref. Section 01-00-00,
caution segment is not illuminated. Table 201) and observe following
conditions on IIDS secondary panel:
(d). Transmission high red %PSI warn
(a). Oil %PSI digital display indicates
ing segment is not illuminated.
approximately 84% PSI.
(e). Transmission oil C digital display (b). High yellow %PSI caution segment is
indicates near ambient temperature. not illuminated.
(f). Transmission low yellow oil C (c). Low red %PSI warning segment is
caution segment is not illuminated. not illuminated.
(g). Transmission high yellow oil C (d). High red %PSI warning segment is
caution segment is not illuminated. not illuminated.
Page 606
(e). Low yellow C caution segment is not (3). Manually rotate one transmission input
illuminated. pinion in the ``drive direction and
observe:
(f). High yellow oil C caution segment is
not illuminated. (a). Rotation is smooth and requires
constant input torque.
(g). High red C warning segment is not (b). Ensure pinion is rotated a minimum
illuminated. of 6 complete revolutions.
(h). CHIPS is not illuminated. (4). Subsequent to the rotational test in the
``drive direction, manually rotate the
(i). ROTOR BRAKE is not illuminated pinion in the reverse direction or
in caution/warning cluster. ``clutch overrunning direction and
(4). Shutdown engine (left or right) per observe:
current Rotorcraft Flight Manual (Ref. (a). Rotation is smooth and requires
Section 01-00-00, Table 201) and constant torque.
observe following conditions on IIDS
secondary panel: (b). Ensure pinion is rotated a minimum
of 6 complete revolutions.
(a). With rotor rpm 70% or less, apply (c). Observe during rotation the other
rotor brake and check for ROTOR input pinion or any output drive
BRAKE illumination in caution/ pinions rotate.
warning cluster.
(5). Repeat steps (3). and (4). for the
(b). On ELECTRICAL MASTER panel opposite transmission input pinion.
set POWER switch to OFF.
(6). Manually rotate the anti-torque fan
(5). With rotor stopped, check transmission pinion in the ``driven direction and
area and components for oil leakage. observe:
None allowed. (a). Rotation is smooth and requires
constant torque.
(6). Inspect for servicing of oil (Ref. Section
12-00-00). (b). Ensure pinion is rotated a minimum
of 6 complete revolutions.
(7). Inspect lubrication pump filter impend
ing bypass indicator for indication of (7). Subsequent to the rotational test of the
impending bypass. Replace lubrication anti-torque fan pinion in the ``driven
pump filter assembly (Ref. Section direction, manually rotate the pinion in
63-21-00) if impending bypass indica the reverse direction and observe:
tor is popped and push in impending (a). Rotation is smooth and requires
bypass indicator. constant torque.
B. Transmission Operational Test Manual (b). Ensure pinion is rotated a minimum
Rotation of 6 complete revolutions.
NOTE: If manual rotation in any direction re C. Chip Detector Test

quires torque that exceeds the specified (1). Remove chip detector (Ref. Section
torque or if manual rotation yields erratic or 63-20-00).
``ratcheting motion, remove transmission
for overhaul. (2). Attach connector to chip detector.
(3). On ELECTRICAL MASTER panel,
(1). Remove transmission input and set POWER switch to BAT/EXT
anti-torque fan drive shafts (Ref. position.
Section 63-10-00).
(4). Short across chip detector probe gap,
(2). Remove main rotor drive shaft (Ref. wait 1 minute 10 seconds and verify
Section 63-10-01). CHIP illuminates on IIDS panel.
Page 607
(5). On ELECTRICAL MASTER panel, (10). If the amount of metal particle deposits
set POWER switch to OFF. have decreased and only small amounts
are found, continue transmission in
(6). Remove short from chip detector. service.
(7). Detach connector from chip detector. E. Transmission Flush Procedure
(8). Install chip detector (Ref. Section
(Ref. CSPSPM)
D. Transmission Serviceability Test Item Nomenclature
(1). Flush main transmission (Ref. Section C106 Oil, Lubricating
12-00-00)
(2). Perform chip detector test. (1). Ground run helicopter per current
Rotorcraft Flight Manual (Ref. Section
NOTE: If test is being performed within 50 01-00-00, Table 201), until transmis
hours of last serviceability test, and filter sion temperature has stabilized.
pop-up indicator is acceptable (Ref. Section
(2). Shutdown helicopter.
12-00-00, Main Transmission Flush), lu
brication pump filter assembly replacement NOTE: Removing chip detector housing pro
is not required. vides a larger drain opening and may en
sure a better flush.
(3). Replace 3 micron transmission filter
and clean or replace 75 micron filter in Oil, Lubricating (C106)
the lubrication pump filter assembly
(Ref. Sections 63-21-00 and
05-20-10).
(4). Service transmission oil (Ref. Section
12-00-00). (3). Remove chip detector and drain
transmission oil immediately while oil
(5). Hover helicopter per current Rotorcraft remains warm.
Flight Manual (Ref. Section 01-00-00,
Table 201), for 20 minutes and (4). Remove chip detector screen/valve
monitor CHIP indicator. (housing) assembly.
(5). Drain transmission oil from heat
(6). Shutdown helicopter and perform chip
exchanger drain valve (Ref. Section
detector inspection.
63-21-00).
(7). If the amount of metal particle deposits
NOTE: Add oil to flush transmission if required
is larger than before transmission oil
for additional cleaning.
change, or contain magnetic chips
larger than 0.14 inch (3.56 mm) in (6). Remove lubrication pump filter assem
any direction, replace transmission. bly (3 and 75 micron filters) (Ref.
Section 63-21-00).
(8). If the amount of metal particle deposits
have decreased and only small amounts NOTE: Ensure lubrication pump filter impend
are found, continue transmission in ing bypass (pop-up) indicator has not popped.
service.
(7). Inspect lubrication pump cavity for
(9). After 5 hours of normal operation, chips or sediment (Ref. Section
perform chip detector inspection. 63-21-00).
Page 608
NOTE: If no particles are found, bypass indicator F. Main Transmission Lubrication Pump
is acceptable. If filters have less than 50 Filter Assembly Cleaning
hours of operational time, there is no need for
filter replacement. Replace only if question Consumable Materials
able. (Ref. CSPSPM)
Item Nomenclature
(8). Ensure chip detector and housing are C106 Oil, Lubricating
clean of any chips or sediment. Install
components but do not safety wire Oil, Lubricating (C106)
housing at this time.
(9). Install lubrication pump filter assembly

(1). The 3 micron filter is not cleanable,
however, it can be flushed by hand in
(10). Refill transmission with lubricating oil lubricating oil (C106).
(C106) (Ref. Section 12-00-00).
(2). The 75 micron filter is cleanable up to 4
times. Ultrasonic clean in lubricating oil
(11). Repeat steps (1). thru (5). (C106) for 30 minutes, and flush by
hand.
(3). Filter and oil to be replaced if aircraft
NOTE: Ensure lubrication pump filter impend has not operated for one year.
ing bypass (pop-up) indicator has not popped.
Filter hours must be transferred
CAUTION to new transmission assembly
(12). Install chip detector and screen/valve log.
(housing) assembly.
(4). Filters moved from one transmission
assembly to another, must be flushed (3
(13). Replenish transmission with oil (Ref. micron) or cleaned (75 micron) and
Section 12-00-00). inspected for general condition.
Page 609
Page 610
GEARBOXES
REPAIRS
1. Main Transmission Assembly Seal (6). Loosen locknut (6) using wrench (T311)
Replacement and remove from input pinion assem
bly.
A. Input Pinion Assembly Seal Replacement
(7). Remove clutch outer race (7) from input
(Ref. Figure 801 and Figure 802) pinion assembly using puller assembly
(T313). (Ref. Figure 802, View B)
(8). Remove the spacer (12) between input
(Ref. CSPSPM) pinion assembly (1) and clutch outer
Item Nomenclature race (7).
or NOTE: Current Configuration clutch outer race
(7, Figure 801) has plasma coating at seal
land area and replaces Early Configuration
C119 Grease, Lubricating clutch outer race (7) and wear sleeve (14).
C322 Marking Ink, Black
(9). Inspect seal lip contact area on clutch
outer race (7).
Special Tools
(Ref. CSPSPM) (a). Current Configuration - No visible
Item Nomenclature depth in the seal lip contact area, nor
T309 Mount Assembly any visible damage to wear surface is
T310 Pusher Assembly allowed. If damaged, replace clutch
T311 Wrench
outer race (7).
T312 Guide (b). Early Configuration - Inspect wear
T313 Puller Assembly sleeve (14) for damage; no visible
T314 Pusher depth in the seal lip contact area, nor
any visible damage to wear surface
T315 Puller Assembly
or flange. Any damage requires
T332 Mount replacement of clutch outer race (7).
T333 Pusher
T345 Pusher NOTE: Replacement of early configuration
clutch outer race (7) and wear sleeve (14)
with current configuration is an upgrade
(1). Remove input pinion assembly (1) (Ref. and re-identification of input pinion assem
Input Pinion Assembly Removal). bly is required.
Cover opening in transmission (10). Disassembly of clutch assembly is not
CAUTION to prevent entry of foreign ob required, unless clutch outer race
jects. replacement or additional inspection is
needed.
(2). Remove retaining ring (2, Figure 801).
(a). Remove clutch (13), bearing (8) from
(3). Remove sleeve (3); discard O-ring (4). clutch outer race (7).
(4). Set mount assembly (T309) on a vise 1). Replace clutch outer race (7) with
and secure input pinion assembly (1) new current configuration.
with bolt. (Ref. Figure 802, View A)
2). Line through existing part number
(5). Remove lockwasher (5, Figure 801) on outer diameter of input pinion
from input pinion assembly using puller assembly (1) with marking ink
assembly (T315). (C322).
Page 801
3). Mark new part number (18). Place spacer (12) in input pinion
900D1400534-101 with marking assembly (1).
ink (C322) next to lined through
marking. (19). Assemble clutch assembly, if disas
Example: sembled for inspection.
900D1400534-101 (new P/N) (a). Install clutch (13) into clutch outer
ASSY 900D1400532-101 (old P/N) race (7), using guide (T312). (Ref.
Figure 802, View E)
(11). Remove seal housing (9); discard
O-ring (10). NOTE: In the next step, clutch outer race must
be rotated counter clockwise while inserting
(12). Remove oil seal (11) from seal housing onto input pinion assembly to allow clutch
(9) using mount (T332) and pusher sprags to disengage from the inner race.
(T333). (Ref. Figure 802, View C)
(20). Install clutch outer race onto input
Grease, Lubricating (C119) pinion assembly
(21). Using pusher assembly (T310), install
bearing (8) onto input assembly (1)
using a hand press. (Ref. Figure 802,
View F)
(13). Apply lubricating grease (C119) to
inner surface of seal housing (9). (22). Set mount assembly (T309) on a vise
and secure input pinion assembly with
(14). Liberally apply lubricating grease a bolt.
(C119) between two lips of oil seal (11,
Figure 801). Wipe off excess grease (23). Apply proper lubricating oil to locknut
spilled over. threads and end surface which contact
with bearing inner race.
(15). Insert oil seal into seal housing using
(24). Install locknut (6, Figure 801) and
pusher (T314). (Ref. Figure 802, View
torque to 1910 - 2120 inch-pounds
D)
(216 - 240 Nm) using wrench (T311).
Oil, Lubricating (C122) NOTE: Ensure two locking tangs of lockwasher
Oil, Lubricating (C106) secure locknut. Use pusher tool (T345) for
lockwasher installation, if required.
(25). Install lockwasher (5) over locknut.
(26). Install new O-ring (4), coated with
Verify proper lubricating oil for proper lubricating oil in groove of sleeve
CAUTION transmission before starting (3).
bricating oil, damage will result. (Ref. Sec (27). Install sleeve onto outer race.
tion 12-00-00, Table 1) (28). Install retaining ring (2).
(16). Apply proper lubricating oil to O-ring (29). Check that the clutch positively
(10, Figure 801) and install on seal engages when outer race is rotated
housing. clockwise.
(17). Insert seal housing into input pinion (30). Install input pinion assembly (Ref.
assembly. Input Pinion Assembly Installation).
Page 802
1 9
10
4
5
6 2
EARLY CONFIGURATION
8
12 13 7
11
14 7
12 13
11 10 9
1
8 6 5 4 2
3
9G63045A
1. INPUT PINION ASSEMBLY 8. BEARING

2. RETAINER RING 9. SEAL HOUSING
3. SLEEVE 10. ORING
4. ORING 11. OIL SEAL
5. LOCKWASHER 12. SPACER
6. LOCKNUT 13. CLUTCH
7. CLUTCH OUTER RACE 14. WEAR SLEEVE
Figure 801. Input Pinion Assembly
Page 803
PULLER ( T315 )
LOCKWASHER
INPUT PINION
ASSEMBLY ROTATE
PULLER ASSEMBLY ( T313 )
MOUNT
( T309 ) BEARING
CLUTCH OUTER RACE
VISE CLUTCH
SPACER
VIEW A
INPUT PINION
LOCKWASHER REMOVAL
INPUT PINION ASSEMBLY
VIEW B
REMOVAL OF THE CLUTCH OUTER RACE
9G63-058
Figure 802. Input Pinion Assembly Seal Replacement Special Tools (Sheet 1 of 2 )
Page 804
PUSH
PUSHER PUSH
(T333) PUSHER
(T314)
OIL SEAL
SEAL HOUSING
SEAL HOUSING
OIL SEAL
VIEW D
MOUNT OIL SEAL INSTALLATION
(T332)
PUSH PUSHER ( T310 )

VIEW C
OIL SEAL REMOVAL
BEARING
CLUTCH
OUTER RACE
E E
PUSH GUIDE
VIEW E - E
MARKING IS VISIBLE AS INPUT PINION
VIEWED FROM ABOVE ASSEMBLY
CLUTCH
INPUT PINION
CLUTCH OUTER RACE
VIEW E
CLUTCH INSTALLATION
VIEW F
BALL BEARING INSTALLATION
9G63059
Figure 802. Input Pinion Assembly Seal Replacement Special Tools (Sheet 2 of 2 )
Page 805
B. Fan Drive Assembly Seal and Wear (7). Remove flange assembly (4) using
Sleeve Replacement puller assembly (T320) (Ref.
Figure 804).
(Ref. Figure 803, Figure 804, Figure 805 and
Figure 806) (8). Inspect wear sleeve (6, Figure 803) for
damage; no visible depth in the seal lip
contact area, nor any visible damage to
Consumable Materials wear surface or flange. Any damage
(Ref. CSPSPM) requires replacement of wear sleeve (6).
Item Nomenclature
(9). Replace damaged wear sleeve (6). Refer
to Figure 805 for tool set-up.
or
NOTE: Wear sleeve flange may have to be cut
prior to attaching remover assembly (T324).
C119 Grease, Lubricating
(a). If installed, mark location of wear
Special Tools sleeve inner end on flange assembly.
(Ref. CSPSPM) (b). If installed, remove wear sleeve
Item Nomenclature flange by cutting edge of flange to
T318 Mount Assembly tear-off groove.
T319 Wrench Assembly (c). Twist and pull wear sleeve flange to
T320 Puller Assembly remove along tear-off groove.
T321 Pusher (d). Remove and discard wear sleeve
T322 Puller Assembly using remover assembly (T324).
T323 Pusher (e). To prevent leaks, remove residual
T324 Remover Assembly wear sleeve adhesive compound from
T325 Pusher flange assembly (4, Figure 803) using
T334 Pusher cloth dampened with solvent (Ref.
General Cleaning).
(1). Drain transmission oil until oil level is
below the sight gauge (Ref. Section NOTE: Until removed, wear sleeve flange will
12-00-00). hold retaining ring and dust seal on flange
assembly (4, Figure 803).
(2). Remove fan drive assembly (Ref. Fan (f). Remove retaining ring (7) and dust
Drive Assembly Removal). seal (8). Clean dust seal.
Cover opening in transmission (g). Install retaining ring (7) on flange
CAUTION to prevent entry of foreign ob assembly (4).
jects.
(h). Install dust seal (8) on flange assem
(3). Set mount assembly (T318) on a vise bly (4). Ensure dust seal protrusion
and secure fan drive assembly (1, around inner diameter faces outside
Figure 803) with bolt. (Ref. Figure 805).
(i). Install new wear sleeve on flange
(4). Remove lockwasher (2, Figure 803)
assembly, use pusher (T323). Align
from fan drive assembly with puller
end of wear sleeve with mark made
assembly (T322) (Ref. Figure 804).
in step (9).(a).
(5). Loosen locknut (3, Figure 803) with NOTE: To prevent wear sleeve deformation and
wrench assembly (T319) and remove it leakage, wear sleeve flange is not removed
from fan drive assembly. after installation.
(6). Remove retaining ring (7) from groove (10). Remove seal housing (10, Figure 803)
of seal housing (10). from fan drive assembly (1).
Page 806
(11). Discard O-rings (5 and 11).
10
1
9 6 8 4
3
2
11 7
5
1 11
5
10 9
6
8
7
3 2
4
P63-047A
1. FAN DRIVE ASSEMBLY 7. RETAINER RING

2. LOCKWASHER 8. DUST SEAL
3. LOCKNUT 9. OIL SEAL
4. FLANGE ASSEMBLY 10. SEAL HOUSING
5. ORING 11. ORING
6. WEAR SLEEVE
Figure 803. Fan Drive Assembly
Page 807
ROTATE
PULLER
(T322)
ROTATE
PULLER
(T320)
FLANGE
ASSEMBLY
LOCKWASHER
FAN DRIVE
ASSEMBLY
FAN DRIVE
MOUNT
(T318)
MOUNT
(T318)
LOCKWASHER REMOVAL
FLANGE ASSEMBLY REMOVAL
9G63060
Figure 804. Fan Drive Assembly Lockwasher and Flange Assembly Removal
Page 808
(12). Replace oil seal (9) in seal housing (10). (14). Apply proper oil to new O-ring (5) and
Refer to Figure 806 for tool set-up. install on fan drive assembly (1).
(a). Remove oil seal (9, Figure 803) from (15). Install seal housing (10) into fan drive
seal housing using pusher (T334). assembly (1).
Grease, Lubricating (C119) Grease, Lubricating (C119)
(16). Liberally apply lubricating grease

(b). Apply lubricating grease (C119) to (C119) to spline teeth of fan drive
inner surface of seal housing (10). assembly (1).
(c). Insert new oil seal into housing using (17). Install flange assembly (4) into fan
pusher (T321). drive assembly.
(d). Liberally apply lubricating grease (18). Apply proper lubricating oil to threads
(C119) between two lips of oil seal (9). of locknut (3) and end surface which
Wipe off excess grease. contacts flange assembly.
Oil, Lubricating (C122) (19). Install locknut into fan drive assembly
Oil, Lubricating (C106) using wrench assembly (T319). Torque
nut to 433 - 520 inch-pounds (48.9 -
58.7 Nm).
NOTE: Ensure two locking tangs of lockwasher
secure locknut. Use pusher tool (T325) for
Verify proper lubricating oil for lockwasher installation, if required.
(20). Install lockwasher (2) onto locknut.
bricating oil, damage will result. (Ref. Sec (21). Install fan drive assembly (Ref. Fan
tion 12-00-00, Table 1) Drive Assembly Installation).
(13). Apply proper oil to new O-ring (11) and (22). Service transmission (Ref. Section
install on seal housing (10). 12-00-00).
Page 809
IF IT EXISTS
WEAR SLEEVE FLANGE
MAY HAVE TO BE CUT
REMOVER PRIOR TO ATTACHING
(T324) PUSH
ROTATE PULLER ASSEMBLY.
PUSHER
(T323)
REMOVAL OF FLANGE
WEAR SLEEVE
DUST SEAL DUST SEAL
FLANGE ASSEMBLY
RETAINING RING
RETAINING RING
FLANGE ASSEMBLY
WEAR SLEEVE REMOVAL WEAR SLEEVE INSTALLATION 9G63050A
Figure 805. Fan Drive Assembly Wear Sleeve Replacement

PUSH PUSH
PUSHER
PUSHER (T321)
(T334)
SEAL HOUSING SEAL HOUSING
OIL SEAL
OIL SEAL
OIL SEAL REMOVAL OIL SEAL INSTALLATION 9G63051

Figure 806. Fan Drive Assembly Oil Seal Replacement
Page 810
C. Blower Drive Pinion Assembly Seal surface or flange. Any damage to wear
Replacement (On Transmission) sleeve requires removal and replace
ment per Blower Drive Pinion Assem
(Ref. Figure 807, Figure 809) bly Seal and Wear Sleeve Replacement.
(5). Replace oil seal (6) in seal housing (4).
Refer to Figure 809 for tool set-up.
(Ref. CSPSPM)
Item Nomenclature (a). Remove oil seal from seal housing
C106 Oil, Lubricating using pusher assembly (T337).
or Grease, Lubricating (C119)
C119 Grease, Lubricating
Special Tools
(Ref. CSPSPM) (b). Apply lubricating grease (C119) to
Item Nomenclature inner surface of seal housing.
T329 Pusher
(c). Insert new oil seal into seal housing
T330 Pusher using pusher (T329).
T331 Remover Assembly
T337 Pusher Assembly
(d). Liberally apply lubricating grease
(C119) between two lips of new oil
seal (6, Figure 807). Wipe off excess
Oil, Lubricating (C122) grease.
(6). Apply proper lubricating oil to O-ring
(7) and install on seal housing.
(7). Install seal housing (4) into blower
drive pinion assembly (1).
CAUTION transmission before starting (8). Install laminated shim (3). If new shim
work. Do not mix different specification lu installed, measure and adjust thickness
bricating oil, damage will result. (Ref. Sec of laminated shim (3) as indicated.
tion 12-00-00, Table 1) (a). Install seal housing and retaining
ring into drive pinion assembly.
(1). Remove oil cooler blower (Ref. Section
63-21-00, Blower Housing Assembly (b). Measure clearance between seal
Removal). housing (4) and retaining ring (2)
with thickness gage. Dial gage may
(2). Remove retaining ring (2, Figure 807) also be used to measure axial end
and laminated shim (3) from blower
play.
drive pinion assembly (1).
(c). Peel laminated shim (3) to obtain
(3). Remove seal housing (4) from blower thickness equal to measured clear
drive pinion assembly. Discard O-ring ance +0.0 / -0.004 inch (+0.0 / -0.1
(7). mm).
Blower drive pinion wear sleeve
CAUTION can not be replaced on the
(d). Remove retaining ring and install
new adjusted shim.
transmission. Blower Drive Pinion Assem
bly must be removed from transmission. (9). Install retaining ring (2).
(4). Inspect wear sleeve (5) for damage; no (10). Install oil cooler blower assembly (Ref.
visible depth in the seal lip contact Section 63-21-00, Blower Housing
area, nor any visible damage to wear Assembly Installation).
Page 811
D. Blower Drive Pinion Assembly Seal and (4). Set mount assembly (T341) on a vise
Wear Sleeve Replacement and secure blower drive pinion assem
bly (1) (Ref. Figure 808 for tool set-up).
(Ref. Figure 807, Figure 808 and Figure 809)
(5). Inspect wear sleeve (5) for damage; no
visible depth in the seal lip contact
area, nor any visible damage to wear
(Ref. CSPSPM)
surface or flange. Any damage requires
Item Nomenclature
replacement of wear sleeve (5).
or (6). Replace damaged wear sleeve (5). Refer
to Figure 808 for tool setup.
C119 Grease, Lubricating Use care not to cut or damage
CAUTION gearshaft or housing bore when
Special Tools removing wear sleeve. Damaged gearshaft
(Ref. CSPSPM) or housing requires replacement of Blower
Item Nomenclature Drive Pinion Assembly.
T329 Pusher (a). Mark location of wear sleeve inner
T330 Pusher end on pinion.
T337 Pusher Assembly (b). Cut wear sleeve with X-ACTO blade
T341 Mount Assembly or flat edged knife.
(c). Grasp cut edge of wear sleeve with
Oil, Lubricating (C122) small-nose pliers, twist and pull to
Oil, Lubricating (C106) remove wear sleeve from pinion.
(d). Remove blower drive pinion assembly
(1) from mount assembly (T341).
(e). To prevent leaks, remove residual
Verify proper lubricating oil for wear sleeve adhesive compound from
CAUTION transmission before starting blower pinion (10, Figure 807) using
work. Do not mix different specification lu cloth dampened with solvent (Ref.
bricating oil, damage will result. (Ref. Sec CSP-SPM, Section 20-20-00,
tion 12-00-00, Table 1) General Cleaning).
(1). Remove blower drive assembly (Ref. (f). Inspect and ensure blower pinion
Blower Drive Assembly Removal). shaft has not been damaged during
wear sleeve removal. Damaged
Cover opening in transmission gearshaft requires replacement of
CAUTION to prevent entry of foreign ob Blower Drive Pinion Assembly.
jects.
(g). Install new wear sleeve (5) on blower
(2). Remove retaining ring (2, Figure 807) drive pinion (1), use pusher (T330).
and laminated shim (3) from blower Align end of wear sleeve with mark
drive pinion assembly (1). made in step (6).(a).
(3). Remove seal housing (4) from blower NOTE: To prevent wear sleeve deformation and
drive pinion assembly. Discard O-ring leakage, wear sleeve flange is not removed
(7). after installation.
Page 812
(7). Replace oil seal (6) in seal housing (4). (10). Install laminated shim (3). If new shim
Refer to Figure 809 for tool set-up. installed, measure and adjust thickness
of laminated shim (3) as indicated.
(a). Remove oil seal from seal housing
using pusher assembly (T337). (a). Install seal housing and retaining
Grease, Lubricating (C119) ring into drive pinion assembly.
(b). Measure clearance between seal

housing (4) and retaining ring (2)
with thickness gage. Dial gage may
also be used to measure axial end
(b). Apply lubricating grease (C119) to
play.
inner surface of seal housing.
(c). Insert seal into seal housing using (c). Peel laminated shim (3) to obtain
pusher (T329). thickness equal to measured clear
ance +0.0 / -0.004 inch (+0.0 / -0.1
(d). Liberally apply lubricating grease mm).
(C119) between two lips of new oil
seal (6, Figure 807). Wipe off excess (d). Remove retaining ring and install
grease. new adjusted shim.
(8). Apply proper lubricating oil to O-ring
(7) and install on seal housing. (11). Install retaining ring (2).
(9). Install seal housing (4) into blower (12). Install blower drive assembly (Ref.
drive pinion assembly (1). Blower Drive Assembly Installation).
Page 813
9 6
10 8
3
7
2
1
10 1
9
8
3 2
9G63052
1. BLOWER DRIVE PINION ASSEMBLY 6. OIL SEAL

2. RETAINING RING 7. ORING
3. LAMINATED SHIM 8. LOCKWASHER
4. SEAL HOUSING 9. LOCKNUT
5. WEAR SLEEVE 10. BLOWER PINION
Figure 807. Blower Drive Pinion Assembly
Page 814
FLANGE OF
WEAR SLEEVE
PUSH
PUSHER
(T330)
WEAR SLEEVE
WEAR SLEEVE
BLOWER PINION
MOUNT ASSEMBLY
(T341)
WEAR SLEEVE REMOVAL

WEAR SLEEVE INSTALLATION
9G63055A
Figure 808. Blower Drive Pinion Assembly Wear Sleeve Replacement
Page 815
PUSH PUSH
PUSHER
(T329)
PUSHER
(T337)
OIL SEAL
SEAL HOUSING
SEAL HOUSING OIL SEAL
SEAL REMOVAL SEAL INSTALLATION

9G63053A
Figure 809. Blower Drive Pinion Assembly Oil Seal Replacement
Page 816
E. Hydraulic Pump Accessory Drive (3). Inspect wear sleeve (2) for damage; no
Assembly Seal and Wear Sleeve visible depth in the seal lip contact
Replacement area, nor any visible damage to wear
surface or flange. Any damage requires
(Ref. Figure 810, Figure 811, and Figure 812) replacement of wear sleeve (2).
Consumable Materials (4). Replace damaged wear sleeve (2). Refer

(Ref. CSPSPM) to Figure 811 for tool setup.
Item Nomenclature
C106 Oil, Lubricating Use care not to cut or damage
or CAUTION gearshaft or housing bore when
C122 Oil, Lubricating removing wear sleeve. Damaged gearshaft
C119 Grease, Lubricating or housing requires replacement of Hydrau
lic Pump Accessory Drive Assembly.
Special Tools
(Ref. CSPSPM) (a). Mark location of wear sleeve inner
Item Nomenclature end on pinion.
T326 Pusher
T327 Pusher (b). Cut wear sleeve with X-ACTO blade
T335 Pusher or flat edged knife.
T336 Mount
T347 Support Assembly (c). Grasp cut edge of wear sleeve with
small-nose pliers, twist and pull to
T348 Mount
remove wear sleeve from pinion.
Oil, Lubricating (C122) (d). To prevent leaks, remove residual

Oil, Lubricating (C106) wear sleeve adhesive compound from
pinion (1, Figure 810) using cloth
dampened with solvent (Ref. CSP-
SPM, Section 20-20-00, General
Cleaning).
CAUTION transmission before starting (e). Inspect and ensure pinion shaft has
work. Do not mix different specification lu not been damaged during wear
bricating oil, damage will result. (Ref. Sec sleeve removal. Damaged gearshaft
tion 12-00-00, Table 1) requires replacement of Hydraulic
(1). Remove hydraulic pump accessory drive Pump Accessory Drive Assembly.
assembly (Ref. Hydraulic Pump
Accessory Drive Assembly Removal). (f). Install new wear sleeve (2) on pinion
(1), use pusher (T327). Align end of
Cover opening in transmission
CAUTION to prevent entry of foreign ob
wear sleeve with mark made in step
(4).(a).
jects.
(2). Set accessory drive assembly on NOTE: To prevent wear sleeve deformation and
support assembly (T347). leakage, wear sleeve flange is not removed.
Page 817
(5). Replace oil seal (9) in seal housing (11). (c). Insert new oil seal into seal housing
Refer to Figure 812 for tool set-up. using pusher (T326) and mount
(T336).
(a). Remove oil seal from seal housing (d). Liberally apply lubricating grease
using pusher (T335) and mount (C119) between two lips of new oil
(T348). Discard oil seal. seal (9, Figure 810). Wipe off excess
grease.
Grease, Lubricating (C119) (6). Apply proper lubricating oil to O-ring
(10) and install on seal housing.
(7). Install seal housing (11) into accessory
drive assembly.
(8). Install accessory drive assembly (Ref.
(b). Apply lubricating grease (C119) to Hydraulic Pump Accessory Drive
inner surface of seal housing. Assembly Installation).
Page 818
5
2
6
10
11
9G63-061
1. PINION 7. LOCKNUT
2. WEAR SLEEVE 8. LOCKWASHER
3. RETAINER 9. OIL SEAL
4. BEARING 10. ORING
5. WASHER 11. HOUSING
6. BOLT
Figure 810. Hydraulic Pump Accessory Drive Assembly
Page 819
FLANGE OF SLEEVE
DETAIL A
PUSH PUSHER
WEAR SLEEVE WEAR SLEEVE

A A
ACCESSORY DRIVE ACCESSORY DRIVE

ASSEMBLY ASSEMBLY
P63-063
Figure 811. Hydraulic Pump Accessory Drive Assembly Wear Sleeve Replacement
PUSH
PUSH
PUSHER
PUSHER
OIL SEAL
SEAL HOUSING
OIL SEAL
SEAL HOUSING
MOUNT
MOUNT
P63-062
Figure 812. Hydraulic Pump Accessory Drive Assembly Oil Seal Replacement
Page 820
Section
632100
Transmission
Lubrication and
Cooling System
TRANSMISSION LUBRICATION AND COOLING SYSTEM

1. Oil Filler Assembly B. Oil Filler Assembly Installation
A. Oil Filler Assembly Removal (Ref. Figure 401)
(Ref. Figure 401)

(1). Open transmission access door assem (Ref. CSPSPM)
bly R210 (Ref. Section 06-00-00). Item Nomenclature
(2). Cut and discard lockwire and discon or
nect flexible drain tubing (2) from oil C122 Oil, Lubricating
filler assembly (1).
(3). Remove bolts (3), washers (4) and nuts C211 Sealing Compound, Corrosion Inhibitive
(5) and remove half clamp (6). C702 Lockwire
(4). Remove sealant from bolts (7).

(5). Remove bolts (7) and washers (8) and Oil, Lubricating (C106)
remove oil filler assembly (1).
(6). Remove and discard O-ring (9).

2 PL CAUTION transmission before starting
7
8 work. Do not mix different specification lu
2 PL
tion 12-00-00, Table 1)
5 3
1 4 (1). Lubricate new O-ring (9) with proper
lubricating oil and install on oil filler
assembly (1).
6
(2). Spray threads of bolts (7) with solid
9
2 (3). Install oil filler assembly (1) with bolts
9G63-019 (7) and washers (8). Torque bolts (7).
1. OIL FILLER ASSEMBLY
2. FLEXIBLE DRAIN TUBING Sealing Compound (C211)
3. BOLT
4. WASHER
5. NUT
6. HALF CLAMP
7. BOLT
8. WASHER (4). Using mechanical fastener sealing
9. ORING
Figure 401. Oil Filler Assembly compound (C211) to heads of bolts (7).
Page 401
(5). Install half clamp (6) around transmis B. Lubrication Pump Assembly Installation
sion mast base strut with bolts (3),
washers (4) and nuts (5). Torque bolts (Ref. Figure 402)
(3).
(6). Connect flexible drain tubing (2) to oil (Ref. CSPSPM)
filler assembly and safety with lockwire Item Nomenclature
(C702). C106 Oil, Lubricating
or
(7). Close transmission access door assem
bly R210 (Ref. Section 06-00-00). C122 Oil, Lubricating
C702 Lockwire
2. Lubrication Pump Assembly C205 Sealing Compound
A. Lubrication Pump Assembly Removal Oil, Lubricating (C122)

(Ref. Figure 402)

53-30-00). Verify proper lubricating oil for
(2). Drain oil from main transmission (2) work. Do not mix different specification lu
(Ref. Section 12-00-00). bricating oil, damage will result. (Ref. Sec
tion 12-00-00, Table 1)
NOTE: Residual oil may remain in oil lines.
When removing oil lines or components, (1). Lubricate new O-rings (9 and 10) with
take precautions to catch oil in a suitable proper lubricating oil and install on
container. lubrication pump (1).
(3). Remove lockwire from oil hoses (3). NOTE: Ensure oil transfer tube (12) is installed
Disconnect oil hoses (3) from pump (1). in transmission (2).
(4). Remove fittings (4) from pump (1) and lubricating oil and install on transfer
discard O-rings (5). tube (12).
(5). Remove sealing compound from pump (3). Align pump (1) with main transmission
(1) and bolts (6). (2).
(4). Install bolts (6) and washers (8). Torque
(6). Cut and discard lockwire between
bolts (6).
mounting bolts (6) and transmission
chip detector (7). Remove bolts (6) and (5). Lubricate new O-rings (5) with proper
washers (8). lubricating oil and install on fittings (4).
(7). Install bolts (6) in jacking holes, or (6). Install fittings (4) in pump (1). Torque
removal screws (13) with 1/4-28 UNF fittings (4).
thread, and alternately tighten to
provide an even pull to remove pump (7). Connect oil hoses (3) to pump. Torque
(1) from transmission (2) and discard hoses (3).
O-rings (9, 10 and 11). (8). Safety hoses (3) with lockwire (C702).
NOTE: Ensure oil transfer tube (12) stays in (9). Safety chip detector (7) to mounting
position in transmission (2). bolt (6) with lockwire (C702).
Page 402
Sealing Compound (C205) application of system pressure and

C. Lubrication Pump Pressure Relief Valve
Removal
method (Ref. CSP-SPM), apply sealing (Ref. Figure 403)
compound (C205) to heads of bolts (6).
(11). Using fillet surface sealing method (Ref. L155 (Ref. Section 53-30-00).
(C205) to parting line of pump (1) and (2). Drain oil from transmission (Ref.
main transmission (2). Section 12-00-00).
(12). Service transmission (Ref. Section NOTE: Residual oil may remain in oil lines.
12-00-00). When removing oil lines or components,
take precautions to catch oil in a suitable
(13). Install forward access door assembly container.
06-00-00). (3). Cut and discard lockwire from pressure
relief valve (1).
mable fluid systems, where mainten (4). Remove pressure relief valve (1) from
ance or replacement of components, lubrication pump (2) and discard
lines, or fittings has occurred, by O-ring (3).
Page 403
13
62 -82 in-lb 10
7.0 - 9.2 Nm
9
6
3 (4 PL)
8
(4-PL)
12
11
2
4
5
1
7
5
4 VIEW ROTATED
3
REMOVAL
9G63-014A
1. LUBRICATION PUMP 8. WASHER

2. TRANSMISSION 9. ORING
3. OIL HOSE 10. ORING
4. FITTING 11. ORING
5. ORING 12. TRANSFER TUBE
6. BOLT 13. REMOVAL SCREWS
7. CHIP DETECTOR
Figure 402. Lubrication Pump Assembly
Page 404
D. Lubrication Pump Pressure Relief Valve E. Lubrication Pump Filter Impending

Installation Bypass Indicator Removal
(Ref. Figure 403)
(Ref. Figure 403)
L155 (Ref. Section 53-30-00).
(Ref. CSPSPM) NOTE: Residual oil may remain in oil lines.
Item Nomenclature When removing oil lines or components,
container.
or
C122 Oil, Lubricating (2). Cut and discard lockwire from filter
Impending Bypass Indicator (14).
C702 Lockwire
(3). Remove filter Impending Bypass
Indicator (14) from lubrication pump (2)
Oil, Lubricating (C122) and discard O-rings (15 and 16).
F. Lubrication Pump Filter Impending
Bypass Indicator Installation
(Ref. Figure 403)
(Ref. CSPSPM)
Item Nomenclature
bricating oil, damage will result. (Ref. Sec C106 Oil, Lubricating
tion 12-00-00, Table 1) or
(1). Lubricate new O-ring (3) and threads C702 Lockwire
of relief valve with proper lubricating
oil and install O-ring on relief valve.
(2). Install pressure relief valve (1) in
lubrication pump (2) and torque relief
valve (1).
(3). Safety relief valve using lockwire

(C702). CAUTION transmission before starting
(4). Service transmission (Ref. Section bricating oil, damage will result. (Ref. Sec
12-00-00). tion 12-00-00, Table 1)
(5). Install forward access door assembly (1). Lubricate new O-rings (15 and 16) and
L155 (Ref. Section 53-30-00). threads of impending bypass indicator
(14) with proper lubricating oil. Install
(6). Verify no leaks are present in flam O-rings on impending bypass indicator.
mable fluid systems, where mainten (2). Install impending bypass indicator (14)
ance or replacement of components, in lubrication pump (2) and torque
lines, or fittings has occurred, by impending bypass indicator.
visual inspection prior to helicopter (3). Safety torque relief valve using lock
being returned to service. wire (C702).
Page 405
(4). Install forward access door assembly Oil, Lubricating (C122)

L155 (Ref. Section 53-30-00). Oil, Lubricating (C106)

lines, or fittings has occurred, by Verify proper lubricating oil for
application of system pressure and CAUTION transmission before starting
visual inspection prior to helicopter work. Do not mix different specification lu
being returned to service. bricating oil, damage will result. (Ref. Sec
tion 12-00-00, Table 1)
G. Lubrication Pump Filter Assembly
Removal (1). Lubricate new O-rings (6 and 7) with
proper lubricating oil and install in new
filters (4 and 5).
(Ref. Figure 403)
NOTE: If a filter is removed from one transmis
(1). Remove forward access door assembly sion assembly and installed in another, fil
L155 (Ref. Section 53-30-00). ter should be cleaned (3 micron - flush only)
(Ref. 63-20-00) and inspected for general
condition before installation. Operation
NOTE: Residual oil may remain in oil lines. hours must be transferred to the new trans
mission log and limited to the original re
placement time requirements (Ref.
container.
05-20-10).
(2). Remove bolts (10) and washers (11). (2). Install new filters (4 and 5) in lubrica
tion pump (2).
(3). Remove lubrication pump housing cover
plate (12). If necessary, install bolts (10) (3). Lubricate new O-ring (9) with proper
in jacking holes and alternately tighten lubricating oil and install on transfer
to provide an even pull to remove cover. tube (8).
Discard O-rings (9 and 13).
lubricating oil and install on lubrication
(4). Remove and discard filters (4 and 5) pump housing cover plate (12).
and O-rings (6 and 7).
(5). Install cover plate (12) with bolts (10)
H. Lubrication Pump Filter Assembly and washers (11). Torque bolts (10).
Installation
(6). Replenish transmission with oil as
required (Ref. Section 12-00-00).
(Ref. Figure 403)
L155 (Ref. Section 53-30-00).
(Ref. CSPSPM)
Item Nomenclature
C106 Oil, Lubricating ance or replacement of components,
or
C122 Oil, Lubricating visual inspection prior to helicopter
Page 406
7 8
9
4 PL 3
11 1
10 13 280 -305 in-lb

31.6 - 34.4 Nm
14
20 -25 in-lb 12
2.2 - 2.8 Nm 16
15 220 -240 in-lb
24.8 - 27.1 Nm
9G63-005A
1. PRESSURE RELIEF VALVE 9. 0RING

2. LUBRICATION PUMP 10. BOLT
3. ORING 11. WASHER
4. FILTER, 3 MICRON 12. LUBRICATION PUMP HOUSING COVER PLATE
5. FILTER, 75 MICRON 13. ORING
6. ORING 14. IMPENDING BYPASS INDICATOR
7. ORING 15. ORING
8. TRANSFER TUBE 16. ORING
Figure 403. Lubrication Pump
Page 407
3. Blower Impeller (9). Remove bolts (11) and washers (12).

Remove blower shroud (13) and shim
A. Blower Impeller Removal (14).
(Ref. Figure 404) (10). Using blower lockwasher puller (T302),
remove and discard bearing locknut
Special Tools retaining lockwasher (15).
(Ref. CSPSPM)
Item Nomenclature (11). Using transmission blower shaft socket
(T303) remove bearing retaining
T302 Lockwasher Puller locknut (16) and washer (17). Remove
T303 Transmission Blower Shaft Socket blower impeller (9) from main transmis
sion (10).
NOTE: This task is typical for left or right blow (12). Remove woodruff key (18) and washer
er impeller removal. (19) from blower drive assembly (20).
(1). Remove forward access door assembly B. Blower Impeller Installation
53-30-00). (Ref. Figure 404)
(2). Remove transmission access door
assembly L210 and R210 (Ref. Section Consumable Materials
53-30-00). (Ref. CSPSPM)
Item Nomenclature
(3). Remove swashplate aft fairing assem C107 Grease, Aircraft
NOTE: Residual oil may remain in oil lines. C702 Lockwire
container. Special Tools
(4). Remove lockwire from oil in hose (1) (Ref. CSPSPM)
and oil out hose (2). Item Nomenclature
T303 Transmission Blower Shaft Socket
(5). Remove transmission oil in hose (1)
from heat exchanger (3).
NOTE: This task is typical for left or right blow
(6). Remove transmission oil out hose (2) er impeller installation.
(1). Install woodruff key (18) and washer
NOTE: If the aircraft has the CURRENT (19) on blower drive assembly (20).
CONFIG Air Conditioning System, refer to
Condenser Assembly Removal (CURRENT Grease, Aircraft (C107)
CONFIG) (Ref. Section 21-50-00).
(7). If necessary, remove the Air Condition
ing Condenser (Ref. Section 21-50-00).
(8). Remove bolts (5 and 7) and washers (6 (2). Lubricate threads of bearing retaining
and 8). Remove cooling interconnect locknut (16) with light coating of
duct (4). aircraft grease (C107).
Page 408
1
8 (4 PL)
7 (4 PL) 43
(NOTE 1)
4
5 (14 PL) 42 (NOTE 3)
(NOTE 1)
6 (14 PL
2
21
22
33
41 (NOTE 3) 3
35
43
10 30 (14 PL)
40
34 26
38 29 (14 PL)
36 (NOTE 1)
23 (2 PL)
(NOTE 1)
39 37 24 (2 PL) 25
(NOTE 1) (2 PL)
44 (NOTE 4) 45 (NOTE 4)
32
20 (6 PL)
19 9
18 16 25
(NOTE 2) (2 PL)
14
17 28 31 (6 PL)
(NOTE 1)
15 27
13
12 (2 PL)
11 (2 PL)
(NOTE 1)
NOTES:
1. TORQUE 36-46 in-lb (4.0-5.1 Nm)
2. TORQUE 160-180 in-lb (18.0-20.3 Nm)
3. TORQUE 50-60 ft-lb (67.8-81.3 Nm)
4. TORQUE 129-179 in-lb (14.6-20.2 Nm)
9G63-007B
Figure 404. Cooling System
Page 409

1. TRANSMISSION OIL IN HOSE 24. BOLT
2. TRANSMISSION OIL OUT HOSE 25. COUNTERSUNK WASHER
3. HEAT EXCHANGER 26. COOLING INLET DUCT
4. COOLING INTERCONNECT DUCT 27. HEAT EXCHANGER MOUNT
5. BOLT 28. HEAT EXCHANGER MOUNT
6. WASHER 29. BOLT
7. BOLT 30. WASHER
8. WASHER 31. BOLT
9. BLOWER IMPELLER 32. WASHER
33. UNION
11. BOLT
34. UNION
12. WASHER
35. ORING
13. BLOWER SHROUD
36. ORING
14. SHIM
15. BEARING LOCKNUT RETAINING LOCKWASHER 37. PLUG AND BLEEDER FITTING
16. BEARING RETAINING LOCKNUT 38. PLUG AND BLEEDER FITTING
17. WASHER 39. ORING
18. WOODRUFF KEY 40. ORING
19. WASHER 41. TRANSMISSION OIL BYPASS VALVE
20. BLOWER DRIVE ASSEMBLY 42. ENGINE OIL BYPASS VALVE
21. ENGINE OIL IN HOSE 43. GASKET, VALVE
22. ENGINE OIL OUT HOSE 44. HEAT EXCHANGER DRAIN VALVE (TRANSMISSION)
23. BOLT 45. HEAT EXCHANGER DRAIN VALVE (ENGINE)
(3). Install blower impeller (9), washer (17) (6). Verify tip clearance between impeller
and bearing retaining locknut (16). (9) and shroud (13) is 0.020-0.024 in.
Using transmission blower shaft socket (0.508-0.609 mm) (Ref. Figure 405).
(T303) torque locknut (16).
(a). If required, remove shroud (13, Ref.
(4). Install blower shroud (13) and shim Figure 404) and adjust shim (14)
(14). thickness to get proper clearance.
Lubricant, Solid Film (C101) (b). If clearance is acceptable, install new

bearing locknut retaining lockwasher
(15).
13
(5). Lubricant threads of bolts (11) using 9

solid film lubricant (C101). Install bolts 0.020 - 0.024 in.
(0.508 - 0.609 mm)
(11) and washers (12). Torque bolts (11).
NOTE:
Peel shim thickness is 0.002-0.003 in.
(0.050-0.076 mm).
Remove peel shim to decrease tip clear
ance. 9G63-009
Add peel shim to increase tip clearance. Figure 405. Impeller Tip Clearance
Page 410
NOTE: If the aircraft has the CURRENT (11). Install oil out hose (2) to heat exchang
CONFIG Air Conditioning System, refer to er (3). Torque hose nut.
Condenser Assembly Installation (CUR
RENT CONFIG) (Ref. Section 21-50-00). (12). Safety oil in hose (1) and oil out hose (2)
(7). If necessary, install the Air Condition
ing Condenser (Ref. Section 21-50-00). (13). Install swashplate aft fairing assembly
T220 (Ref. Section 53-30-00).
(8). Install cooling interconnect duct (4)
bolts (5).
assembly L210 and R210
(9). Install bolts (7) and washers (8). Torque (Ref. Section 53-30-00).
bolts (7).
(10). Install oil in hose (1) to heat exchanger L155 and R155
(3). Torque hose nut. (Ref. Section 53-30-00).
36 -46 in-lb
4.0 - 5.1 Nm
2
(4 PL)
1
6 (4 PL)
3 (4 PL)
4
5
5(4 PL) 9G63-008
1. COOLING EXHAUST DUCT 4. BLOWER HOUSING ASSEMBLY
2. BOLT 5. BOLT
3. WASHER 6. WASHER
Figure 406. Blower Housing Assembly
Page 411
4. Blower Housing Assembly Sealing Compound (C211)

A. Blower Housing Assembly Removal
(Ref. Figure 406)
NOTE: This task is typical for left or right blow (4). Using mechanical fastener sealing
er housing removal. method (Ref. CSP-SPM), seal bolts (5)
with sealing compound (C211).
(1). Remove blower impeller
(Ref. Section 63-21-00). (5). Install cooling exhaust duct (1).
(2). Remove cooling exhaust duct (1). Lubricant, Solid Film (C101)
Remove bolts (2) and washers (3).
(3). Remove adhesive and lockwire from
bolts (5). Remove bolts (5), washers (6)
and blower housing assembly (4).
(6). Lubricate threads of bolts (2) using
B. Blower Housing Assembly Installation solid film lubricant (C101). Install bolts
(Ref. Figure 406)
(7). Install blower impeller (Ref. Section
63-21-00).
(Ref. CSPSPM) 5. Heat Exchanger Assembly
Item Nomenclature
C101 Lubricant, Solid Film A. Heat Exchanger Assembly Removal
C702 Lockwire (Ref. Figure 404)
NOTE: This task is typical for left or right heat
exchanger removal.
NOTE:
This task is typical for left or right blower L155 and R155 (Ref. Section
housing installation. 53-30-00).
Align blower housing hole marked L
with bottom hole of blower drive assem (2). Remove transmission access door
bly for left side. assembly L210 and R210 (Ref. Section
53-30-00).
Align blower housing hole marked R
with bottom hole of blower drive assem (3). Remove swashplate forward fairing
bly for right side. assembly T155 (Ref. Section 53-30-00).
Lubricant, Solid Film (C101) (4). Remove swashplate aft fairing assem
(5). Remove forward fairing support
(1). Using solid film lubricant (C101) spray NOTE: Residual oil may remain in oil lines.
threads of bolts (5). When removing oil lines or components,
(2). Install blower housing assembly (4), container.
bolts (5) and washers (6). Torque bolts
(5). (6). Remove transmission oil in hose (1, Ref.
Figure 404) from heat exchanger (3).
(3). Using lockwire (C702) lockwire bolts
(5). (7). Remove lockwire from oil out hose (2).
Page 412
(8). Remove transmission oil out hose (2) B. Heat Exchanger Assembly Installation
(Ref. Figure 404)
(9). Remove lockwire from oil in hose (21)
and oil out hose (22). Consumable Materials
(Ref. CSPSPM)
(10). Remove engine oil in hose (21) from Item Nomenclature
heat exchanger (3). C106 Oil, Lubricating
or
(11). Remove engine oil out hose (22) from C122 Oil, Lubricating
heat exchanger (3).
C702 Lockwire
NOTE: If the aircraft has the CURRENT
CONFIG Air Conditioning System, refer to
Condenser Assembly Removal (CURRENT Oil, Lubricating (C122)
CONFIG) (Ref. Section 21-50-00). Oil, Lubricating (C106)
(12). If necessary, remove the Air Condition

ing Condenser (Ref. 21-50-00
(13). Remove cooling interconnect duct (4) by Verify proper lubricating oil for
removing bolts (5 and 7) and washers (6 CAUTION transmission before starting
and 8). work. Do not mix different specification lu
(14). Remove sealing compound from heat tion 12-00-00, Table 1)
exchanger mount bolts (23 and 24).
NOTE:
(15). Remove mount bolts (23 and 24) and This task is typical for left or right heat
countersunk washers (25). exchanger installation.
If the aircraft has the CURRENT CON
(16). Remove heat exchanger, cooling inlet FIG Air Conditioning System, refer to
duct (26) and heat exchanger mounts Condenser Assembly Installation (CUR
(27 and 28) as a unit. RENT CONFIG) (Ref. Section 21-50-00).
(1). If necessary, install the Air Condition

(17). Remove bolts (29 and 31) and washers ing Condenser (Ref. Section 21-50-00).
(30 and 32).
(2). Attach cooling inlet duct (26) to heat
NOTE: If replacing heat exchanger with like exchanger (3) with bolts (29) and
new item, perform following steps. washers (30). Torque bolts (29).
(3). Attach heat exchanger mounts (27 and

(18). Remove unions (33 and 34) from heat 28) to heat exchanger (3) and cooling
exchanger (3) and discard O-rings (35 inlet duct (26) with bolts (31) and
and 36). washers (32). Torque bolts (31).
(19). Cut and discard lockwire and remove (4). Install heat exchanger (3) cooling inlet
heat exchanger plug and bleeder duct (26) and mounts (27 and 28) with
fittings (37 and 38) and discard O-rings bolts (23 and 24) and countersunk
(39 and 40). washers (25). Torque bolts (23 and 24).
Page 413
Sealing Compound (C211) lines, or fittings has occurred, by

(5). Using mechanical fastener sealing assembly T155 (Ref. Section 53-30-00).
method (Ref. CSP-SPM), seal bolts (23
and 24) with sealing compound (C211). (21). Install swashplate aft fairing assembly
T220 (Ref. Section 53-30-00).
(6). Install cooling interconnect duct (4).
Install bolts (5 and 7) and washers (6 (22). Install forward access door assembly
and 8). Torque bolts (5 and 7). L155 and R155 (Ref. Section
53-30-00).
(7). If removed, install unions (33 and 34)
in heat exchanger (3). Lubricate new (23). Install transmission access door
O-rings (35 and 36) with proper assembly L210 and R210 (Ref. Section
lubricating oil and install on unions (33 53-30-00).
and 34).
6. Thermal Bypass Valve
(8). Torque unions (33 and 34).
A. Thermal Bypass Valve Removal
(9). If removed, install heat exchanger plug
and bleeder fittings (37 and 38). (Ref. Figure 404)
Lubricate new O-rings (39 and 40) NOTE:
with proper lubricating oil and install
on plug and bleeder fittings (37 and 38). The thermal bypass valves are compo
nents of the heat exchanger assembly.
(10). Torque plug and bleeder fitting (37 and This task is typical for left or right hand
38). (transmission oil and/or engine oil) ther
mal bypass valve removal.
(11). Safety plug and bleeder fittings (37 and
38) with lockwire (C702). (1). Remove forward access door assembly
(12). Install oil in hose (1) and oil out hose 53-30-00).
(2) to heat exchanger (3). Torque hose
nut. (2). Remove transmission access door
assembly L210 and R210 (Ref. Section
(13). Safety oil in hose (1) and oil out hose (2) 53-30-00).
(3). Remove swashplate forward fairing
(14). Install oil in hose (21) and oil out hose assembly T155 (Ref. Section 53-30-00).
(22) to heat exchanger (3). Torque hose
nut. (4). Remove swashplate aft fairing assem
(15). Safety oil in hose (21) and oil out hose
(22) with lockwire (C702). (5). Remove forward fairing support
(16). Install forward fairing support assem
bly (Ref. Section 53-30-00). NOTE: Residual oil may remain in heat ex
changers. When removing thermal bypass
(17). Service transmission (Ref. Section valve, take precautions to catch oil in a suit
12-00-00). able container.
(18). Service engine (Ref. Section 12-00-00). (6). Remove lockwire from thermal bypass
valve (41 or 42).
mable fluid systems, where mainten (7). Remove bypass valve (41 or 42) from
ance or replacement of components, heat exchanger (3).
Page 414
B. Thermal Bypass Valve Installation (2). Install new valve gasket (43) onto
thermal bypass valve (41 or 42).
(Ref. Figure 404)
(3). Install thermal bypass valve (41 or 42)
into heat exchanger (3) and torque
bypass valve (41 or 42).
(Ref. CSPSPM)
Item Nomenclature (4). Safety thermal bypass valve (41 or 42)
C106 Oil, Lubricating with lockwire (C702).
or
(5). Install forward fairing support assem
C122 Oil, Lubricating bly (Ref. Section 53-30-00).
C702 Lockwire
12-00-00).
Oil, Lubricating (C106) (7). Service engine (Ref. Section 12-00-00).
Verify proper lubricating oil for application of system pressure and
CAUTION transmission before starting visual inspection prior to helicopter
work. Do not mix different specification lu being returned to service.
tion 12-00-00, Table 1) (9). Install swashplate forward fairing
NOTE:
This task is typical for left or right hand (10). Install swashplate aft fairing assembly
(transmission oil and/or engine oil) ther T220 (Ref. Section 53-30-00).
mal bypass valve installation. (11). Install forward access door assembly
If thermal bypass valve is reinstalled, L155 and R155 (Ref. Section
valve gasket must be replaced with new 53-30-00).
one.
(1). Apply a thin coat of proper lubricating assembly L210 and R210 (Ref. Section
oil to new valve gasket (43). 53-30-00).
Page 415
Page 416
MAIN TRANSMISSION LUBRICATION AND COOLING SYSTEM

INSPECTION / TEST
1. Lubrication System (3). Inspect impeller blades for cracks, nicks
or damage. No damage allowed.
A. Lubrication System Inspection
(4). Inspect for rubbing on blower shroud.
(Ref. Figure 402) None allowed.
(1). Open transmission access door assem (5). Inspect for security of bearing retaining
bly L210 and R210 (Ref. Section lockwasher. Replace if loose.
06-00-00). (6). Inspect housing for cracks, nicks and
debris. No damage allowed.
(2). Inspect hoses, fittings and lubrication
pump for leaks and security. No leaks (7). Install cooling interconnect duct.
allowed. Torque or replace loose or (8). Close transmission access door assem
missing hardware. bly L210 and R210 (Ref. Section
(3). Inspect heat exchanger, fittings and 06-00-00).
hoses for leaks and security. No leaks B. Cooling Ducts Inspection
allowed. Torque or replace loose or
missing hardware. (1). Open transmission access door assem
(4). Inspect electrical connections at oil 06-00-00).
temperature switch, pressure switch, (2). Inspect for cracks, deterioration and
speed pickup and chip detector for security. No damage allowed. Torque or
corrosion and security of connectors replace loose or missing hardware.
(Ref. Section 63-20-00). No corrosion
allowed. (3). Inspect for debris. None allowed.
(5). Inspect oil temperature switch, pres (4). Close transmission access door assem
sure switch, speed pickup and chip bly L210 and R210 (Ref. Section
detector for leaks and security. No leaks 06-00-00).
allowed. C. Heat Exchanger Inspection
(6). Inspect lubrication filter impending (1). Open transmission access door assem
bypass indicator for indication of bly L210 and R210 (Ref. Section
impending bypass. Replace filter if 06-00-00).
impending bypass indicator is popped. (2). Inspect for dents. If dents are greater
(7). Close transmission access door assem than 0.125 inch (3.2 mm) deep,
bly L210 and R210 (Ref. Section replace heat exchanger.
06-00-00). (3). Inspect for nicks and scratches. Repair
nicks and scratches that are less than
2. Cooling System 0.0312 inch (0.88 mm) deep.
A. Cooling Blower Impeller and Housing (4). Inspect for loose, damaged, or missing
Inspection nut plates and rivets. None allowed.
(Ref. Figure 404) (5). Using 3-power magnifying glass,

inspect for cracks. None allowed.
(1). Open transmission access door assem (6). Inspect for corrosion. Remove corrosion.
06-00-00). (7). Close transmission access door assem
(2). Remove cooling interconnect duct. 06-00-00).
Page 601
(8). Inspect each aft heat exchanger mount (9). Inspect the flange area that surrounds
web for cracks near the lower outboard the third nutplate from the bottom on
bolt hole. Use a 3X power magnifying the forward side of the heat exchanger.
glass. No cracks permitted. Use a 3X power magnifying glass.
Reference Figure 601. No cracks permitted.
Reference Figure 601.
NOTE 1
CONDENSER NOT SHOWN FOR CLARITY.
NOTE 2
LEFT SIDE SHOWN
NOTES 1.). INSPECT NUTPLATE AREA FOR CRACKS.

2) INSPECT AFT MOUNT OUTBOARD WEB FOR CRACKS. 9G63040
Figure 601. Heat Exchanger and Mounts
Page 602
MAIN TRANSMISSION LUBRICATION AND COOLING SYSTEM

REPAIRS
1. Heat Exchanger Repairs B. Nicks and Scratches Removal
A. Corrosion Removal
(Ref. CSPSPM)
Item Nomenclature
(Ref. CSPSPM)
Item Nomenclature C432 Cleaner
C432 Cleaner C814 Abrasive Paper
C814 Abrasive Paper C813 Nylon Abrasive Mat
C813 Nylon Abrasive Mat C241 Alodine
C241 Alodine
(1). Using a Swiss file followed by abrasive
(1). Using abrasive paper (C814), remove paper (C814), remove nicks and
light surface corrosion. Lightly rub scratches.
undamaged finish around repair area to
obtain a smooth surface. Cleaner (C432)
Cleaner (C432)
(2). Clean repair area with nylon abrasive

mat (C813) soaked with cleaner (C432)
(2). Clean repair area with nylon abrasive diluted with 15 parts of water to 1 part
mat (C813) soaked with cleaner (C432) of cleaner. Rub lightly.
diluted with 15 parts of water to 1 part
of cleaner. Rub lightly. (3). Flush repair area with clean water to
remove all cleaner from heat exchanger.
(3). Flush repair area with clean water to Ensure that no cleaner is caught in
remove all cleaner from heat exchanger. irregular surfaces.
Ensure that no cleaner is caught in
irregular surfaces. (4). Inspect for water beads on repair area.
(4). Inspect for water beads on repair area. If water beads are present, clean repair
If water beads are present, clean repair area again with weakened water
area again with weakened water emulsion cleaner and flush with water.
emulsion cleaner and flush with water. Alodine (C241)
Alodine (C241)
(5). Brush on adhesion promoter (C242) so

(5). Brush on alodine (C241) so that all that all repaired surfaces are fully
repaired surfaces are fully coated. coated. Allow 1 hour of drying time
Allow 1 hour of drying time and apply and apply a second coat of chemical
a second coat of chemical film. film.
Page 801
Page 802
Section
632200
Rotor Brake
ROTOR BRAKE
FAULT ISOLATION
1. Rotor Brake System Troubleshooting The troubleshooting tables should be used

with the simplified system schematics,
electrical wiring diagrams, serviceability tests
(Ref. Figure 101) and other detailed procedures in this and other
chapters of the manual.
brief summary of rotor brake system faults, in the Rotorcraft Maintenance Manual
Table 101. Rotor Brake System Troubleshooting

Rotor Brake will not apply System low on fluid. Service reservoir. 120000
sufficient pressure to slow
rotor. Air in rotor brake system. Bleed rotor brake system. 120000
Brake head assembly Repair brake head assembly. 010000
leaking. (Ref. Related Manufacturers
Publications)
Lining worn excessively. Replace lining. (Ref. Related 010000
Manufacturers Publications)
binding of caliper (head) Lightly lubricate guide bolts, 632200
hardware springs and slide bore of lining
using spray lubricant (C120)
loose or worn bolts or Replace bolts, springs and 632200
bushings that attach caliper bushings (as a set).
(head) assembly.
Rotor Brake handle has rotor brake head is not Lightly lubricate guide bolts, 632200
abnormal vibration or moving smoothly due to springs and slide bore of lining
ratcheting or irregular feel binding hardware using spray lubricant (C120)
when applied.
loose or worn bolts or Replace bolts, springs and 632200
bushings that attach caliper bushings (as a set).
(head) assembly.
Rotor Brake chatters when Rotor RPM too high. Allow rotor speed to decrease
applied. and reapply.
Brake disk worn unevenly. Remove and replace brake 632200
disk.
ROTOR BRAKE CAUTION Faulty wiring. Test and repair wiring. 980000
light does not illuminate when
brake is applied. Faulty proximity switch. Replace proximity switches. 010000
(Ref. Related Manufacturers
Publications)
Page 101
63-22-00 Original
Table 101. Rotor Brake System Troubleshooting (Cont.)

ROTOR BRAKE CAUTION Faulty wiring. Test and repair wiring. 980000
light illuminated when handle
stowed. Faulty proximity switch. Replace proximity switches. 010000
(Ref. Related Manufacturers
Publications)
Jammed piston assembly or Repair brake head assembly. 010000
adjuster pin slippage. (Ref. Related Manufacturers
Publications)
A2 PROXIMITY SWITCH
IIDS W129 (ROTOR BRAKE)
W123 J155 P155 P522 J1
J4 P104
ROTOR BRAKE 1 ENGAGED
(BRAKE ON = OPEN) N G C OUTPUT
GS107-C
A620 H B
E COMMON
CB33 A 16-32VDC
RTR BRK
J3 P377
PROXIMITY SWITCH
5A X J (ROTOR BRAKE)
P523 J1
Y K A 16-32VDC
BAT
BUS
GS105-C
E L B COMMON
W122 A612 M C OUTPUT
J5 P105 P170 J3 J1 P171
(BRAKE ON = GND) D 52 11
J3 P103 TB2-1
ROTOR BRAKE INSTALLED 41 94 M J
S R N
GS102-K
E 92 D C A
9G630281
EFFECTIVITY: 00010 - 00034
Figure 101. Rotor Brake Wiring Diagram (Sheet 1 of 2)
Page 102
A2 ROTOR BRAKE
IIDS W129 1 SENSOR
W123 J155 P155 P522 J1
J4 P104
(BRAKE ON = OPEN) N G C OUTPUT
A601 GS107-C
CIRCUIT BREAKER PANEL E H B COMMON
CB7 (900 CONFIG) A 16-32VDC

CB13 (902 CONFIG)
IIDS J2 P128
W124
7.5A 7
BAT
BUS
A612
P174 J9 TB2-7 ROTOR BRAKE
J1 P171 2 SENSOR
G A
P523 J1
114 J
E 115 K A 16-32VDC
W122
F
GS105-C
J5 P105 P170 J3 E L B COMMON
(BRAKE ON = GND) D 52 C OUTPUT
11 M
J3 P103 TB2-1
ROTOR BRAKE INSTALLED 41 94 M J
S R N
GS102-K
E 92 D C A
9G630282
EFFECTIVITY: 00035 & SUBS
Figure 101. Rotor Brake Wiring Diagram (Sheet 2 of 2)
Page 103
Page 104
ROTOR BRAKE
1. Rotor Brake System Hydraulic Fluid (C112)
A. Rotor Brake Bleeding
(4). Fill container with enough hydraulic

(Ref. Figure 301)
fluid (C112) to submerge free end of
drain line (T2017) (to prevent backflow
of air).
(Ref. CSPSPM) (5). Release rotor brake handle by raising
Item Nomenclature up 0.5 inch (12.7 mm) and rotating
handle 15 degrees clockwise, then
C112 Hydraulic Fluid lower handle down.
(6). Open bleeder valve (2).
(7). Close bleeder valve (2) (finger tight),
Special Tools release rotor brake handle.
(Ref. CSPSPM)
Item Nomenclature (8). Repeat steps (5)., (6)., and (7). three
times.
T2017 Drain Line
(9). Service rotor brake (Ref. Section
12-00-00).
(1). Open transmission access door assem (10). Repeat steps (8). and (9). until fluid
bly R210 (Ref. Section 06-00-00). output from bleed port is free from all
air bubbles.
(2). Remove screw (1). (11). Remove drain line (T2017) and tighten
bleeder valve (2).
(12). Install screw (1).
(3). Attach drain line (T2017) to bleeder
valve (2). Place free end of drain line in (13). Close transmission access door assem
a suitable clean container. bly R210 (Ref. Section 06-00-00).
Page 301
63-22-00 Original
1
9G63034
1. SCREW 2. BLEEDER VALVE

Figure 301. Rotor Brake Bleeding
Page 302
Original 63-22-00
ROTOR BRAKE
1. Rotor Brake Head Assembly B. Rotor Brake Head Assembly Installation
(Ref. Figure 401)
A. Rotor Brake Head Assembly Removal
(Ref. CSPSPM)
C702 Lockwire
(1). Open transmission access door assem
bly L210 and R210 (Ref. Section NOTE: Ensure there is adequate clearance be
06-00-00). tween brake linings to fit over rotor brake
disc. Running clearance to be 0.060-in.
(1.524 mm) between disk and linings.
(2). Detach connectors P522 (3) and P523
(4). (1). Install rotor brake head assembly (1)
on main transmission (2). Install bolts
NOTE: Take precautions to catch hydraulic
fluid with container and/or rags. (2). Safety bolts (9) with lockwire (C702).
CAUTION
Hydraulic Fluid (C112) (3). Remove cap and plug and connect
hydraulic line (5) and torque tube nut
(Ref. CSP-SPM).
(4). Install screw (7) and washer (8) in
clamp (6). Torque screw (7).
(5). Attach connectors P522 (3) and P523
(3). Disconnect hydraulic line (5) from rotor (4).
brake head assembly (1). Install cap
and plug. (6). Bleed rotor brake (Ref. Section
63-22-00).
(4). Remove screw (7), washer (8) and mable fluid systems, where mainten
clamp (6) from hydraulic tube (5). ance or replacement of components,
(5). Cut and discard lockwire from bolts (9). visual inspection prior to helicopter
(6). Remove bolts (9) and washers (10). (8). Close transmission access door assem
Remove rotor brake head assembly (1) bly L210 and R210 (Ref. Section
from main transmission (2). 06-00-00).
Page 401
63-22-00 Original
2. Rotor Brake Lining Compound, Anti-Seize (C220)
A. Rotor Brake Lining Removal
(Ref. Figure 401)

(2). Install bushings (23), springs (20) and
bolts (19). Apply anti-seize compound
(1). Remove rotor brake head assembly (1)
(C220) to bolts (19) threads.
Lubricant, Spray (C120)
(2). Cut and discard lockwire from bolts
(19).
Springs can eject and cause in

CAUTION jury. Hold springs in place to (3). Apply light coat of spray lubricant
prevent ejection during bolt removal. (C120) to bolts (19), springs (20) and
slide bore of lining (21). Activate
(3). Remove bolts (19), springs (20), bush (stroke) brake mechanism to run-in
ings (23) and linings (21) from brake lubricant.
head assembly (1). (4). Torque bolts (19) and secure with
lockwire (C702).
(5). Install rotor brake head assembly (1)
3. Rotor Brake Proximity Switch
A. Rotor Brake Proximity Switch Removal
NOTE: Hardware and other related metal com
ponents should be wiped clean of excess lin (Ref. Figure 401)
ing (pad) dust using isopropyl alcohol (C419) (1). Remove connector P522 (3) or P523 (4).
or other equivalent cleaners.
(2). Cut and discard lockwire.
B. Rotor Brake Lining Installation (3). Remove proximity switch (22).
(Ref. Figure 401) NOTE: Cover opening to prevent foreign object

entry if proximity switch is not replaced im
mediately
B. Rotor Brake Proximity Switch Installation
(Ref. CSPSPM)
C220 Compound, AntiSeize Consumable Materials
(Ref. CSPSPM)
Item Nomenclature
C702 Lockwire
C702 Lockwire
(1). Install rotor brake linings (21) with (1). Install proximity switch (22). Torque
abrasive surface toward disk. proximity switch (22).
(2). Secure proximity switch (22) with
NOTE: If bolts (19) are being replaced with new lockwire (C702).
hardware, replace bolts (19), bushings (23)
and springs (20) as a set. (3). Attach connector P522 (3) or P523 (4).
Page 402
11
4 PL
15 4 PL 13
14 12
16
5
18
21
6
12 -15 in-lb 3 2
1.3 - 1.6 Nm 7
20
17
23 REF. 3
1
(2 PL)
19 (2 PL)
37 - 42 in-lb
4.2 - 4.7 Nm 9 10
4 PL
150 - 160 in-lb 4
16.9 - 18.1 Nm 22
9G63-015B
1. ROTOR BRAKE HEAD 13. NUT

2. MAIN TRANSMISSION 14. BOLT
3. CONNECTOR (P522) 15. WASHER
4. CONNECTOR (P523) 16. WASHER
5. HYDRAULIC TUBE 17. SCREW
6. CLAMP 18. BLEEDER VALVE
7. SCREW 19. BOLT
8. WASHER 20. SPRING
9. BOLT 21. LINING
10. WASHER 22. PROXIMITY SWITCH
11. ROTOR BRAKE DISK 23. BUSHING
12. FLANGE
Figure 401. Rotor Brake Head and Rotor Brake Disk
Page 403
63-22-00 Original
4. Rotor Brake Disk 5. Rotor Brake Control Linkage

A. Rotor Brake Control Linkage Removal
A. Rotor Brake Disk Removal
(Ref. Figure 402)
(Ref. Figure 401)
(1). Release rotor brake handle by raising
up 0.5 inch (12.7 mm) and rotating
(1). Remove anti-torque driveshaft (Ref. handle 15 degrees clockwise, then
Section 63-10-00). lower handle down.
(2). Remove rotor brake head assembly (2). Remove and discard cotter pin (4).
(Ref. Section 63-22-00). (3). Remove washer (5) and pin (6).
(3). Remove nuts (13), washers (15 and 16) (4). Remove bolts (7 and 8) and washers (9).
and bolts (14) from disk (11). Remove B. Rotor Brake Control Linkage Installation
rotor brake disk (11) from flange (12).
(Ref. Figure 402)
B. Rotor Brake Disk Installation (1). Install control linkage (1), bolts (11),
washers (12) and nuts (10). Torque nuts
(Ref. Figure 401) (10).
(2). Install bolts (7 and 8) and washers (9).
(1). Install rotor brake disk (11) on flange
Torque bolts (7 and 8).
(12). Install bolts (14), washers (15 and
16) and nuts (13). Torque nuts (13). (3). Install pin (6), washer (5) and new
cotter pin (4).
(2). Install rotor brake head assembly (Ref.
Section 63-22-00). (4). Stow rotor brake handle by pushing up
into stow bracket (2).
(3). Install anti-torque drive shaft (Ref. (5). Check rotor brake rigging (Ref. Section
Section 63-10-00). 63-22-00).
Page 404
Revision 5 63-22-00
6. Rotor Brake Stow Lock Bracket 7. Rotor Brake Hydraulic Control Valve
A. Rotor Brake Hydraulic Control Valve
A. Rotor Brake Stow Lock Bracket Removal Removal
(Ref. Figure 402)
(Ref. Figure 402) (1). Open forward access door assembly
R155 (Ref. Section 06-00-00).
(1). Release rotor brake handle by raising (2). Remove and discard cotter pin (4).
up 0.5 inch (12.7 mm) and rotating
handle 15 degrees clockwise, then (3). Remove washer (5) and pin (6).
lower handle down. (4). Remove hose clamp assembly (18).
(5). Remove screws (19), washers (20) and
(2). Remove nuts (10), bolts (11) and closeout assembly (21).
washers (12). Remove stow (2).
(6). Remove tiedown strap (13) and flexible
tubing (14).
B. Rotor Brake Stow Lock Bracket NOTE: Take precautions to catch hydraulic
Installation fluid with container and/or rags.
(Ref. Figure 402) CAUTION

(1). Install stow bracket (2), bolts (11),
washers (12) and nuts (10). Torque nuts
(10).
(7). Disconnect hydraulic line (15) from

(2). Stow rotor brake handle by pushing up rotor brake control valve (3). Install cap
into stow bracket (2). and plug.
(3). Check rotor brake rigging (Ref. Section Remove rotor brake control valve (3)
63-22-00). and plate assembly (22).
Page 405
63-22-00 Original
24
27
26
25
30
29
32
REF. 15 28
33
32 31
14
33
13 REF. 15
9 9 34
8 7
15
3
8 16
17
23
1
9 20 18
(4 PL)
19
(4 PL)
2
REF. 1
10 5
4 22
12
6 21
11
12
5
3 PLACES
9G63-031
Figure 402. Rotor Brake Control Linkage
Page 406
Original 63-22-00

1. ROTOR BRAKE CONTROL LINKAGE ASSEMBLY 18. HOSE CLAMP ASSEMBLY
2. ROTOR BRAKE HANDLE STOW BRACKET 19. SCREW
3. ROTOR BRAKE HYDRAULIC CONTROL VALVE 20. WASHER
ASSEMBLY 21. ROTOR BRAKE CONTROL CLOSEOUT ASSEMBLY
4. COTTER PIN 22. ROTOR BRAKE CLOSEOUT PLATE ASSEMBLY
5. WASHER 23. BOOT
6. PIN 24. NUT
7. BOLT
25. SCREW
8. BOLT
26. WASHER
9. WASHER
27. CLAMP
10. NUT
11. BOLT 28. NUT
13. TIEDOWN STRAP 30. WASHER
14. FLEXIBLE TUBING 31. CLAMP
15. HYDRAULIC LINE 32. BOLT
16. BOLT 33. WASHER
17. WASHER 34. CLAMP BLOCK
B. Rotor Brake Hydraulic Control Valve (7). Install flexible tubing (14) with split
Installation facing forward and push down against
(Ref. Figure 402) rotor brake control valve (3). Install
new tiedown strap (13) approximately
(1). Prepare surface for electrical bond (Ref. at middle of tube nut.
CSP-SPM).
(2). Install plate assembly (22) on rotor
brake control valve (3). Install bolts (8). Check rotor brake rigging (Ref. Section
(16) and washers (17). Torque bolts 63-22-00).
(16).
(3). Install closeout assembly (21), screws
(19) and washers (20). Torque screws (9). Bleed rotor brake (Ref. Section
(19). 63-22-00).
(4). Install hose clamp assembly (18).
(5). Install pin (6) and washer (5). Install (10). Verify no leaks are present in flam
new cotter pin (4). mable fluid systems, where mainten
(6). Remove cap and plug and connect
hydraulic line (15) on rotor brake
control valve (3) and torque tube nut (11). Close forward access door assembly
(Ref. CSP-SPM). R155 (Ref. Section 06-00-00).
Page 407
63-22-00 Original
8. Rotor Brake Hydraulic Tube Assembly B. Rotor Brake Hydraulic Tube Assembly
Installation
A. Rotor Brake Hydraulic Tube Assembly (Ref. Figure 402)
Removal
(Ref. Figure 402)
(1). Open forward access door assembly

R155 and L155 (Ref. Section (1). Install hydraulic line (15), clamp block
06-00-00). (34), bolts (32) and washers (33).
(2). Open transmission access door assem (2). Remove cap and plug and connect
bly L210 (Ref. Section 06-00-00). hydraulic line (15) on rotor brake
control valve (3).
(3). Remove tiedown strap (13) and flexible (3). Remove cap and plug and connect
tubing (14). hydraulic line (5, Ref. Figure 401) on
rotor brake head assembly (1).
NOTE: Take precautions to catch hydraulic (4). Install screw (7) and washer (8) in
fluid with container and/or rags. clamp (6). Torque screw (7).
(5). Install clamps (27, Ref. Figure 402),
CAUTION screws (25), washers (26) and nuts (24).
Torque nuts (24).
Hydraulic Fluid (C112) (6). Install clamp (31), screw (29), washer
(30) and nut (28). Torque nut (28).
(7). Torque tube nut on line (15) (Ref.
CSP-SPM).
(8). Install flexible tubing (14) with split
(4). Disconnect hydraulic line (15) from facing forward and push down against
rotor brake control valve (3). Install cap rotor brake control valve (3). Install
and plug. new tiedown strap (13) approximately
at middle of tube nut.
(5). Disconnect hydraulic line (5, Ref. (9). Torque tube nut on line (5, Ref.
Figure 401) from rotor brake head Figure 401), (Ref. CSP-SPM).
assembly (1). Install cap and plug.
(10). Bleed rotor brake (Ref. Section
63-22-00).
clamp (6) from hydraulic tube (5). (11). Verify no leaks are present in flam
(7). Remove nuts (24, Ref. Figure 402),
screws (25), washers (26) and clamps
(27).
(8). Remove nut (28), screw (29), washer
(30) and clamp (31). (12). Close forward access door assembly
R155 and L155 (Ref. Section
06-00-00).
(9). Remove bolts (32), washers (33) and
clamp block (34). Remove hydraulic line (13). Close transmission access door assem
(15). bly L210 (Ref. Section 06-00-00).
Page 408
Original 63-22-00
ROTOR BRAKE
INSPECTION / TEST / RIGGING
1. Rotor Brake B. Rotor Brake Rigging
A. Rotor Brake Inspection (Ref. Figure 601)
Consumable Materials Consumable Materials

(Ref. CSPSPM) (Ref. CSPSPM)
Item Nomenclature Item Nomenclature
C419 Alcohol, Isopropyl C702 Lockwire
(1). Inspect rotor brake disc for wear, (1). Release rotor brake handle (1) from
grooves and security. Minimum disk stowed position by raising the lever
thickness 0.478 inch (12.14 mm). arm up 0.5 inch (12.7 mm). Rotate
Torque or replace loose or missing handle approximately 15 degrees
hardware. clockwise, then lower handle down
approximately 5 to 10 degrees.
(2). Inspect disk for cracks. None allowed.
(2). Remove safety wire and loosen nuts (2)
(3). Inspect rotor brake head for cracks. on lower link (3). Allow approximately
None allowed. 0.13 inch (3.3 mm) clearance between
adjusting nuts and rotor brake handle
(4). Inspect rotor brake head for fluid linkage (4). (Enough so that lower link
leakage, corrosion and security. No can slide forward and backward.)
leakage or corrosion allowed. Torque or
replace loose or missing hardware. (3). Stow rotor brake handle (1). Inspect to
ensure lower link (3) is still loose.
(5). Inspect rotor brake lining for wear, and
deterioration. Carrier & Lining Min. (4). Adjust lower link (3) by tightening
Thickness 0.233 inch. (5.92 mm). forward or aft nuts (2) until rotor brake
(Ref. Related Manufactures Publica handle (1) just touches bottom of piston
tions 01-00-00). (5), so that there is no compression on
piston.
(5). Torque nuts (2) and secure with
lockwire (C702).
C. Rotor Brake Operational Check
(1). Run-up aircraft rotor to 100% operat
(6). Clean bolts, springs, bushings and
ing speed per current Rotorcraft Flight
lining carrier using isopropyl alcohol
Manual (Ref. 900RFM-1 900 CONFIG
(C419) or equivalent cleaner. Inspect
or CSP-902RFM-1 902 CONFIG).
for corrosion, cracks, nicks, gouges or
distortion. If damage is found, replace (2). Perform normal aircraft shutdown.
affected components (bolts, bushings Apply rotor brake below 70% Nr.
and springs are to be replaced as a set).
(3). Release rotor brake pressure during
(7). Inspect lining to disk clearances. last revolution of rotor.
Minimum clearance not less than 0.060
inch (1.52 mm). (4). Rotor must come to a complete stop
between (15 - 45 seconds) from the
(8). Inspect rotor brake connectors for time brake pressure is applied until the
security. Tighten connectors. blades stop rotating.
Page 601
3
2
(NOTE)
2
(NOTE)
5
1
NOTE: SPECIAL TORQUE 165 -195 in-lb (18.64 - 22.03 Nm)

9G63-032
1. ROTOR BRAKE HANDLE 4. ROTOR BRAKE HANDLE LINKAGE
2. NUT 5. PISTON
3. LOWER LINK
Figure 601. Rotor Brake Rigging
Page 602
Original 63-22-00
ROTOR BRAKE
REPAIRS
1. Rotor Brake Assembly B. Rotor Brake Disk Repairs
A. Rotor Brake Head Repairs
For repairs to rotor brake head refer to For repairs to rotor brake disk refer to Related
Related Manufacturers Publications (Ref. Manufacturers Publications (Ref. Section
Section 01-00-00). 01-00-00).

63-22-00 Original
Section
633000
Main Rotor Static
Mast
MAIN ROTOR STATIC MAST

1. Main Rotor Static Mast Assembly (6). Remove nuts (11), washer (12), counter
sunk washer (13) and bolts (14).
A. Static Mast Removal Remove static mast (1).
(Ref. Figure 402) NOTE: If replacing static mast with like new
item, perform the following steps.
Consumable Materials (7). Remove mixer pivot supports (Ref.

(Ref. CSPSPM) Section 63-30-00).
Item Nomenclature (8). Remove actuator supports (Ref. Section
T905 Mast Lifting Tool 63-30-00).
(9). Remove main rotor drive shaft lower
seal (Ref. Section 63-10-00).
(1). Remove swashplate assembly (Ref.
Section 62-30-00). B. Static Mast Installation
(Ref. Figure 402)
(2). Remove transmission assembly (Ref.
Section 63-20-00).
(3). Attach mast lifting tool (T905) (3, Ref. (Ref. CSPSPM)
Figure 401) to static mast (1) with main Item Nomenclature
rotor hub nut (2). Attach hoist to lifting T905 Mast Lifting Tool
tool.
(1). Attach mast lifting tool (T905) (3, Ref.
Figure 401) to static mast (1) with main
rotor hub nut (2). Attach hoist to tool.
3
2
(2). Install bolts (14, Ref. Figure 402),
countersunk washer (13), washer (12)
1 and nuts (11). Torque nuts (11).
(3). Install new cotter pins (10).
(4). Torque nuts (15). Remove mast tool.
NOTE: If replacing static mast with like new
item, perform steps (5)., (6). and (7).
(5). Install mixer pivot supports (Ref.
Section 63-30-00).
(6). Install actuator supports (Ref. Section
63-30-00).
9G63-029 (7). Install main rotor drive shaft lower seal
1. STATIC MAST (Ref. Section 63-10-00).
2. MAIN ROTOR HUB NUT
3. MAST LIFTING TOOL (T905) (8). Install transmission assembly (Ref.
Section 63-20-00).
Figure 401. Static Mast Lifting
(9). Perform engine to transmission
(4). Loosen, but do not remove nuts (15, alignment inspection (Ref. Section
Ref. Figure 402). 71-00-00).
(10). Install swashplate assembly (Ref.
(5). Remove and discard cotter pins (10). Section 62-30-00).
Page 401
63-30-00 Original
42
22 21
48
49
10
1400 -1700 in-lb
20 130 -180 in-lb 11 158.14 - 192.03 Nm
47 19 14.68 - 20.33 Nm 12
46
2 PL
18 13
41 14
70-90 in-lb
7.9 - 10.16 Nm 1
45 44 7
43
39 4 PLACES
40 2 PL
6
600-900 in-lb 5
9
67.77 - 101.66 Nm
8 4
38 37
2 3
36
35
17
(2 PL)
34 16 23
(2 PL)
28
15 27
(2 PL) 26
33 24
550 - 650 in-lb
62.12 - 73.42 Nm
29
30 RIGHT FORWARD 25
STRUT ONLY
31
70.90 in-lb
7.9-10.16 Nm
32
4 PLACES
9G63-026
Figure 402. Main Rotor Static Mast
Page 402
Original 63-30-00

1. MAIN ROTOR STATIC MAST 26. WASHER
2. LEFT HAND FORWARD TRUSS STRUT 27. COUNTERSUNK WASHER
3. LEFT HAND MIDDLE FORWARD TRUSS STRUT 28. BOLT
4. LEFT HAND MIDDLE AFT TRUSS STRUT 29. NUT
5. LEFT HAND AFT TRUSS STRUT 30. WASHER
6. RIGHT HAND AFT TRUSS STRUT 31. BONDING JUMPER
7. RIGHT HAND MIDDLE AFT TRUSS STRUT 32. NUT
8. RIGHT HAND MIDDLE FORWARD TRUSS STRUT 33. PRELOAD INDICATOR WASHER (PLI)
9. RIGHT HAND FORWARD TRUSS STRUT 34. BOLT
10. COTTER PIN 35. LEFT HAND FORWARD TRUSS DECK FITTING
11. NUT
36. LEFT HAND AFT TRUSS DECK FITTING
12. WASHER
37. RIGHT HAND AFT TRUSS DECK FITTING
13. COUNTERSUNK WASHER
38. RIGHT HAND FORWARD TRUSS DECK FITTING
14. BOLT
39. COTTER PIN
15. NUT
16. WASHER 40. NUT
17. BOLT 41. WASHER
18. COTTER PIN 42. MIXER PIVOT SUPPORT
20. WASHER 44. NUT
21. COUNTERSUNK WASHER 45. WASHER
22. BOLT 46. COUNTERSUNK WASHER
23. ACTUATOR SUPPORT TIE STRAP 47. BOLT
24. COTTER PIN 48. LEFT HAND ACTUATOR SUPPORT
25. NUT 49. RIGHT HAND ACTUATOR SUPPORT
2. Truss Strut Assembly NOTE: After torquing nuts (15), check for a
minimum gap of 0.05 inch (1.27 mm) un
A. Left Hand Forward Truss Strut Removal der washer at bolt head and a minimum gap
of 0.05 inch (1.27 mm) at nut side.
(Ref. Figure 402)
(4). Install new cotter pin (10).
(1). Remove swashplate forward fairing (5). Install clamps.
assembly T155 (Ref. Section 53-30-00). (6). Install swashplate forward fairing
(2). Remove clamps.
C. Left Hand Middle Forward Truss Strut
(3). Remove and discard cotter pin (10). Removal
(Ref. Figure 402)
(4). Remove nut (11), washer (12), counter
sunk washer (13) and bolt (14). (1). Remove swashplate forward fairing
assembly T155 and L210 fairing (Ref.
(5). Remove nuts (15), washers (16) and Section 53-30-00).
bolts (17). Remove strut (2). (2). Remove clamps.
B. Left Hand Forward Truss Strut (3). Remove and discard cotter pin (10).
Installation (4). Remove nut (11), washer (12), counter
sunk washer (13) and bolt (14).
(Ref. Figure 402)
(1). Install strut (2), bolts (17), washers (16) bolts (17). Remove strut (3).
and nuts (15). D. Left Hand Middle Forward Truss Strut
Installation
(2). Install bolt (14), countersunk washer
(Ref. Figure 402)
(13), washer (12) and nut (11).
(1). Install strut (3), bolts (17), washers (16)
(3). Torque nuts (11 and 15). and nuts (15).
Page 403
63-30-00 Original
(2). Install bolt (14), countersunk washer G. Left Hand Aft Truss Strut Removal
(13), washer (12) and nut (11).
(Ref. Figure 402)
(3). Torque nuts (11 and 15).
NOTE: After torquing nuts (15), check for a assembly T155, L210 and T220 fairings
minimum gap of 0.05 inch (1.27 mm) un (Ref. Section 53-30-00).
der washer at bolt head and a minimum gap
of 0.05 inch (1.27 mm) at nut side. (2). Remove and discard cotter pin (10).
(4). Install new cotter pin (10). (3). Remove nut (11), washer (12), counter
(5). Install clamps.
bolts (17). Remove strut (5).
assembly T155 and L210 fairing (Ref.
Section 53-30-00). H. Left Hand Aft Truss Strut Installation
E. Left Hand Middle Aft Truss Strut Removal (Ref. Figure 402)
(Ref. Figure 402)
(1). Remove swashplate forward fairing and nuts (15).
assembly T155, L210 and T220 fairings
(Ref. Section 53-30-00). (2). Install bolt (14), countersunk washer
(13), washer (12) and nut (11).
(2). Remove clamps.
NOTE: After torquing nuts (15), check for a
(4). Remove nut (11), washer (12), counter minimum gap of 0.025 inch (0.635 mm)
sunk washer (13) and bolt (14). under washer at bolt head and a minimum
gap of 0.025 inch (0.635 mm) at nut side.
bolts (17). Remove strut (4). (4). Install new cotter pin (10).
F. Left Hand Middle Aft Truss Strut (5). Install swashplate forward fairing
Installation assembly T155, L210 and T220 fairings
(Ref. Figure 402)
(1). Install strut (4), bolts (17), washers (16) I. Right Hand Forward Truss Strut Removal
and nuts (15). (Ref. Figure 402)
(13), washer (12) and nut (11).
assembly T155 and R210 fairing (Ref.
(3). Torque nuts (11 and 15). Section 53-30-00).
NOTE: After torquing nuts (15), check for a (2). Remove clamps.
der washer at bolt head and a minimum gap (3). Remove sealing compound, nut (29),
of 0.05 inch (1.27 mm) at nut side. washer (30) and bonding jumper (31).
(4). Install new cotter pin (10). (4). Remove and discard cotter pin (10).
(5). Install clamps. (5). Remove nut (11), washer (12), counter
assembly T155, L210 and T220 fairings (6). Remove nuts (15), washers (16) and
(Ref. Section 53-30-00). bolts (17). Remove strut (9).
Page 404
Original 63-30-00
J. Right Hand Forward Truss Strut (4). Remove nut (11), washer (12), counter
Installation sunk washer (13) and bolt (14).
(Ref. Figure 402) (5). Remove nuts (15), washers (16) and
Consumable Materials L. Right Hand Middle Forward Truss Strut
(Ref. CSPSPM) Installation
Item Nomenclature
(Ref. Figure 402)
and nuts (15).
and nuts (15). (2). Install bolt (14), countersunk washer
(13), washer (12) and nut (11).
(13), washer (12) and nut (11). (3). Torque nuts (11 and 15).
(3). Torque nuts (11 and 15). NOTE: After torquing nuts (15), check for a
NOTE: After torquing nuts (15), check for a der washer at bolt head and a minimum gap
minimum gap of 0.05 inch (1.27 mm) un of 0.05 inch (1.27 mm) at nut side.
der washer at bolt head and a minimum gap
of 0.05 inch (1.27 mm) at nut side. (4). Install new cotter pin (10).
(5). Install clamps.
(5). Install clamps. assembly T155, R210 and T220 fairings
(6). Prepare surface for electrical bond (Ref. (Ref. Section 53-30-00).
CSP-SPM). M. Right Hand Middle Aft Truss Strut
(7). Install bonding jumper (31), washer Removal
(30) and nut (29). Torque nut (29). (Ref. Figure 402)
Sealing Compound (C205) (1). Remove swashplate forward fairing
assembly T155, R210 and T220 fairings
(2). Remove half clamp from oil filler.
(8). Using sealing compound (C205), seal (3). Remove and discard cotter pin (10).
nut (29) (Ref. CSP-SPM).
(9). Install swashplate forward fairing sunk washer (13) and bolt (14).
assembly T155 and R210 fairing (Ref.
Section 53-30-00).
K. Right Hand Middle Forward Truss Strut N. Right Hand Middle Aft Truss Strut
Removal Installation
(1). Remove swashplate forward fairing (1). Install strut (7), bolts (17), washers (16)
assembly T155, R210 and T220 fairings and nuts (15).
(2). Remove clamps. (13), washer (12) and nut (11).
(3). Remove and discard cotter pin (10). (3). Torque nuts (11 and 15).
Page 405
63-30-00 Original
NOTE: After torquing nuts (15), check for a 3. Truss Deck Fitting Assembly
der washer at bolt head and a minimum gap A. Left Hand Forward Truss Deck Fitting
of 0.05 inch (1.27 mm) at nut side. Removal
(4). Install new cotter pin (10). (Ref. Figure 402)
(5). Install half clamp from oil filler. (1). Remove left hand forward truss and left
hand middle forward truss (Ref. Section
(6). Install swashplate forward fairing 63-30-00).
assembly T155, R210 and T220 fairings
(Ref. Section 53-30-00). (2). Remove forward roof/insulation panel
O. Right Hand Aft Truss Strut Removal
(3). Remove sealing compound from bolt
(Ref. Figure 402) (34) and truss fitting (35).
(1). Remove swashplate forward fairing (4). Remove nut (32), bolt (34), and PLI
assembly T155, R210 and T220 fairings washer (33). Discard PLI washer (33).
(Ref. Section 53-30-00). Remove truss fitting (35).
(2). Remove clamps. B. Left Hand Forward Truss Deck Fitting
Installation
(Ref. Figure 402)
(5). Remove nuts (15), washers (16) and (Ref. CSPSPM)
bolts (17). Remove strut (6). Item Nomenclature
P. Right Hand Aft Truss Strut Installation
(Ref. Figure 402)
(1). Install truss fitting (35), bolt (34), new
(1). Install strut (6), bolts (17), washers (16) PLI washer (33) and nut (32).
and nuts (15). (2). Torque bolt (34) in the following
(2). Install bolt (14), countersunk washer method.
(13), washer (12) and nut (11). (a). Hold bolt (34), insert scribe (or
(3). Torque nuts (11 and 15). equivalent), into hole of new PLI
washer (33).
NOTE: After torquing nuts (15), check for a
minimum gap of 0.025 inch (0.635 mm) NOTE: Torque is correct when washer (33) no
under washer at bolt head and a minimum longer turns.
gap of 0.025 inch (0.635 mm) at nut side. Do not continue to tighten bolt
CAUTION after washer no longer turns.
Damage to washer, bolt, and nut will occur.
(5). Install clamps. Washer, bolt and nut must be replaced if
over-torque occurs.
assembly T155, R210 and T220 fairings (b). Tighten bolt (34) 1/8 turn at a time
(Ref. Section 53-30-00). while turning washer (33).
Page 406
Sealing Compound (C211) (a). Hold bolt (34), insert scribe (or
equivalent), into hole of new PLI
washer (33).
NOTE: Torque is correct when washer (33) no

longer turns.
(3). Using sealing compound (C211), seal
bolt (34) using mechanical fastener Do not continue to tighten bolt
sealing method (Ref. CSP-SPM). CAUTION after washer no longer turns.
Damage to washer, bolt, and nut will occur.
(4). Using sealing compound (C211), seal Washer, bolt and nut must be replaced if
around truss fitting (35) using fillet over-torque occurs.
surface sealing method (Ref. CSP-
SPM). (b). Tighten bolt (34) 1/8 turn at a time
while turning washer (33).
(5). Install forward roof/insulation panel
(Ref. Section 25-20-00). Sealing Compound (C211)
(6). Install left hand forward truss and left
hand middle truss (Ref. Section
63-30-00).
C. Left Hand Aft Truss Deck Fitting Removal (3). Using sealing compound (C211), seal
bolt (34) using mechanical fastener
(Ref. Figure 402)
sealing method (Ref. CSP-SPM).
(1). Remove left hand middle aft truss and
left hand aft truss (Ref. Section
around truss fitting (36) using fillet
63-30-00).
(2). Remove aft roof/insulation panel (Ref. SPM).
Section 25-20-00).
(5). Install aft roof/insulation panel (Ref.
(3). Remove sealing compound from bolt Section 25-20-00).
(34) and truss fitting (36).
(6). Install left hand middle aft truss and
(4). Remove nut (32), bolt (34), and PLI left hand aft truss (Ref. Section
washer (33). Discard PLI washer (33). 63-30-00).
Remove truss fitting (36).
E. Right Hand Forward Truss Deck Fitting
D. Left Hand Aft Truss Deck Fitting Removal
Installation
(Ref. Figure 402)
(Ref. Figure 402)
(1). Remove right hand forward truss and
right hand middle forward truss (Ref.
Consumable Materials Section 63-30-00).
(Ref. CSPSPM)
Item Nomenclature (2). Remove forward roof/insulation panel
C211 Sealing Compound, Corrosion Inhibitive (Ref. Section 25-20-00).

(1). Install truss fitting (36), bolt (34), new (34) and truss fitting (38).
PLI washer (33) and nut (32).
(4). Remove nut (32), bolt (34), and PLI
(2). Torque bolt (34) in the following washer (33). Discard PLI washer (33).
method. Remove truss fitting (38).
Page 407
F. Right Hand Forward Truss Deck Fitting G. Right Hand Aft Truss Fitting Deck
Installation Removal

(1). Remove right hand middle aft truss and
right hand aft truss (Ref. Section
63-30-00).
(Ref. CSPSPM)
Item Nomenclature (2). Remove aft roof/insulation panel (Ref.
C211 Sealing Compound, Corrosion Inhibitive Section 25-20-00).
(34) and truss fitting (37).
(1). Install truss fitting (38), bolt (34), new
PLI washer (33) and nut (32). (4). Remove nut (32), bolt (34), and PLI
washer (33). Discard PLI washer (33).
(2). Torque bolt (34) in the following Remove truss fitting (37).
method.
H. Right Hand Aft Truss Fitting Deck
Installation
(a). Hold bolt (34), insert scribe (or
equivalent), into hole of new PLI (Ref. Figure 402)
washer (33).
NOTE: Torque is correct when washer (33) no (Ref. CSPSPM)
longer turns. Item Nomenclature
Do not continue to tighten bolt C211 Sealing Compound, Corrosion Inhibitive
Damage to washer, bolt, and nut will occur. (1). Install truss fitting (37), bolt (34), new
Washer, bolt and nut must be replaced if PLI washer (33) and nut (32).
over-torque occurs.
(2). Torque bolt (34) in the following
(b). Tighten bolt (34) 1/8 turn at a time method.
while turning washer (33). (a). Hold bolt (34), insert scribe (or
equivalent), into hole of new PLI
Sealing Compound (C211) washer (33).
NOTE: Torque is correct when washer (33) no
longer turns.
Do not continue to tighten bolt
bolt (34) using mechanical fastener Damage to washer, bolt, and nut will occur.
sealing method (Ref. CSP-SPM). Washer, bolt and nut must be replaced if
over-torque occurs.
(4). Using sealing compound (C211), seal (b). Tighten nut (32) 1/8 turn at a time
around truss fitting (38) using fillet while turning washer (33).
SPM). Sealing Compound (C211)
(5). Install forward roof/insulation panel

(6). Install right hand forward truss and (3). Using sealing compound (C211), seal
right hand middle truss (Ref. Section bolt (34) using mechanical fastener
63-30-00). sealing method (Ref. CSP-SPM).
Page 408
(4). Using sealing compound (C211), seal (2). Remove nut (25), washer (26), counter
around truss fitting (37) using fillet sunk washer (27) and bolt (28).
SPM). (3). Remove and discard cotter pin (18).
(5). Install aft roof/insulation panel (Ref. (4). Remove nut (19), washer (20), counter
Section 25-20-00). sunk washer (21), bolt (22) and actua
tor support tie strap (23).
(6). Install right hand middle aft truss and
right hand aft truss (Ref. Section B. Actuator Support Tie Strap Installation
63-30-00). (Ref. Figure 402)
4. Mixer Pivot Support Assembly NOTE: This task is typical for left or right hand
actuator support tie strap installation.
A. Mixer Pivot Support Removal
(Ref. Figure 402) (1). Install actuator support tie strap (23),
bolt (22), countersunk washer (21),
NOTE: This task is typical for left or right hand washer (20) and nut (19).
mixer pivot support removal.
(1). Remove mixer assembly (Ref. Section (27), washer (26) and nut (25).
62-30-00).
(4). Install new cotter pins (18 and 24).
(3). Remove nut (40), washers (41) and
mixer pivot support (42). 6. Actuator Support Assembly
B. Mixer Pivot Support Installation A. Actuator Support Removal
NOTE: This task is typical for left or right hand (1). Remove actuator support tie straps
mixer pivot support installation. (Ref. Section 63-30-00).
(1). Install mixer pivot support (42), (2). Remove and discard cotter pin (43).
washers (41) and nut (40). Torque nut
(40).
sunk washer (46), bolt (47) and actua
(2). Install new cotter pin (39). tor supports (48 and 49).
(3). Install mixer assembly (Ref. Section B. Actuator Support Installation

62-30-00).
(Ref. Figure 402)
5. Actuator Support Tie Strap Assembly (1). Install actuator support (48 and 49),
A. Actuator Support Tie Strap Removal bolt (47), countersunk washer (46),
washer (45) and nut (44). Torque nut
(Ref. Figure 402) (44).
NOTE: This task is typical for left or right hand (2). Install new cotter pin (43).
actuator support tie strap removal.
(3). Install actuator support tie straps (Ref.
(1). Remove and discard cotter pin (24). Section 63-30-00).

63-30-00 Original
MAIN ROTOR STATIC MAST

INSPECTION
1. Main Rotor Static Mast NOTE: The areas for corrosion Internal Dimen
sion (ID) inspection is the top area of the
A. Main Rotor Static Mast Inspection static mast.
(Ref. Figure 601)
(7). Inspect top area of inside of mast
(1). Inspect static mast for nicks, dents and (entire circumference) for evidence of
scratches. No damage allowed. cracks or pitting using bright light and
(2). Inspect swashplate slider bearing 10x magnification.
journal on static mast for wear.
No damage allowed. No cracks allowed. If cracks are
found remove static mast from
(3). Inspect for worn or missing paint. service.
Reference Main Rotor Static Mast
Support-Base Assembly Paint Repair If pitting is found go to Main Rotor
63-30-00. Static Mast Inside Dimension (ID)
Pitting Repair for possible repair.
(4). Inspect internal static mast for paint
chips. Reference Main Rotor Static
Mast Support-Base Assembly Paint INTERNAL AREA
Repair 63-30-00. INSPECTION
LOWER BEARING
NOTE: The Outer Dimension (OD) areas for BOSS
corrosion inspection are the:
lower angled area. CRITICAL AREA
0.125 (3.175mm)
open area below the lower bearing boss. BELOW BEARING
critical area of 0.125 inch (3.175 mm) just CORROSION
BOSS
below the lower bearing boss. INSPECTION AREAS
(5). Check for corrosion that does not

penetrate to the base material. The
corrosion will be white in color.
(a). If corrosion is found, reference
63-30-00 Main Rotor Static Mast
White-Corrosion Repair.
9B63-037A
(6). Check for corrosion that penetrates to
the base material (red or dark brown in
color) in the areas that follow:
Figure 601. Static Mast
(a). Check for corrosion in the open area
less than 0.125 inch (3.175 mm)
below the lower bearing boss and B. Mixer Pivot Support Inspection
away from from the boss radius.
None allowed. No repair allowed. (1). Inspect mixer pivot support for cracks
(b). Maximum repairable depth is and corrosion. No damage allowed.
0.005 inch (0.127 mm) in the remain
ing inspection areas. Reference (2). Inspect bearing for binding, catching,
63-30-00 Main Rotor Static Mast corrosion, metal chips and other
Base-Material Corrosion Repair. damagme. No damage allowed.

MAIN ROTOR STATIC MAST SUPPORT

REPAIR
1. Main Rotor Static Mast Support Repair
CAUTION
A. Main Rotor Static MastWhite Corrosion Do not use a mechanical grinder to re
Repair move corrosion. It can cause too much
heat in repair areas.
(Ref. Figure 801) Corrosion removal must not go into the
area 0.125 in. (3.175 mm) immediately
below lower bearing boss.
(Ref. CSPSPM)
(2). Remove corrosion, use scouring pad
Item Nomenclature
(C817).
C308 Primer NOTE:
C429 Solvent Cleaner Cadmium plating must be done as speci
fied in QQ-P-416 Type II Class 2, mini
C802 Cloth, NonLint
mum thickness 0.0003 in. (0.3 mil).
Cadmium plating must be applied by an
Commercial Plating, Cadmium individual or service center that is ap
QQP416 Type II Class 2 proved by the equipment manufacturer
for the brush plating procedure.
You must use an approved low embrittle
CAUTION ment solution for all brush plating proce
dures.
The lower bearing boss is a critical area.
No repair is permitted on the lower bear (3). If cadmium plating was removed, touch
ing boss. up cadmium plating. Use a brush on
procedure.
The area 0.125 in. (3.175 mm) immedi
ately below lower bearing boss is a critical Solvent Cleaner (C429)
area. No repair is permitted in this area.
Repair is permitted on lower angled area
between mast base and nickel plated sur
face.
Repair is permitted in open area that is (4). Clean area with solvent cleaner (C429)
more than 0.125 in. (3.175 mm) below and a non-lint cloth (C802). Clean
lower bearing boss and above nickel surface with another clean cloth before
plated surface. solvent evaporates.
(5). Clean again and again until cloth stays

Solvent Cleaner (C429) clean.
(6). Apply masking tape around repair area

and on data plate.
(7). Dry main rotor static mast in air for a

(1). Clean repair area with solvent cleaner minimum of 15 minutes before you
(C429) and a non-lint cloth (C802). apply primer.
Page 801
Primer (C308)
CAUTION
The lower bearing boss is a critical area.
No repair is permitted on the lower bear
ing boss.
(8). Apply primer (C309)to repair area of The area 0.125 in. (3.175 mm) immedi
static mast. Dry film thickness of ately below lower bearing boss is a critical
0.0006-0.0010 in. (0.015-0.025 mm) area. No repair is permitted in this area.
(Ref. CSP-SPM, Section 20-30-00). Repair is permitted on lower angled area
(9). Dry in air for a minimum of one hour between mast base and nickel plated sur
before you apply finish enamel. face.
Repair is permitted in open area that is
Finish Enamel, White (C302) more than 0.125 in. (3.175 mm) below
lower bearing boss and above nickel
plated surface.
(10). Apply white finish enamel (C302) to

primed areas of static mast. Dry film
thickness of 0.0017-0.0025 in.
(0.043-0.064 mm) (Ref. CSP-SPM, (1). Clean repair area with solvent cleaner
Section 20-30-00). (C429) and a non-lint cloth (C802).
(11). Dry in air for a minimum of eight
hours. CAUTION
B. Main Rotor Static Mast Material Do not use a mechanical grinder to re

Corrosion Repair move corrosion. It can cause too much
heat in repair areas.
(Ref. Figure 801) Corrosion removal must not go into the
area 0.125 in. (3.175 mm) immediately
below lower bearing boss.
(Ref. CSPSPM) NOTE:
Item Nomenclature
Measure repair area before and after ma
C302 Finish Enamel, White terial removal. Maximum material re
C308 Primer moval permitted, 0.005 in. (0.127 mm).
C429 Solvent Cleaner Make pits smooth on an area 10 times the
C802 Cloth, NonLint dimension of the depth dimension.
C807 Sandpaper (2). Remove corrosion, use sandpaper
Commercial Plating, Cadmium (C807) or finer. Move sandpaper
QQ-P-416 Type II Class 2 parallel to mast center line and not
radially.
Page 802
NOTE: Finish Enamel, White (C302)

Cadmium plating must be done as speci
mum thickness 0.0003 in. (0.3 mil).
Cadmium plating must be applied by an (10). Apply white finish enamel (C302) to
individual or service center that is ap primed areas of static mast. Dry film
proved by the equipment manufacturer thickness of 0.0017-0.0025 in.
for the brush plating procedure. (0.043-0.064 mm) (Ref. CSP-SPM,
You must use an approved low embrittle Section 20-30-00).
ment solution for all brush plating proce (11). Dry in air for a minimum of eight
dures. hours.
(3). Touch up cadmium plating, use a brush
on procedure.
Solvent Cleaner (C429) LOWER BEARING CRITICAL AREA

BOSS. NO REPAIR 0.125 IN. (3.175mm)
PERMITTED. BELOW BEARING
BOSS. NO REPAIR
PERMITTED.
(4). Clean area with solvent cleaner (C429) AREAS WHERE

CORROSION CAN BE
and a non-lint cloth (C802). Clean REPAIRED.
surface with another clean cloth before
solvent evaporates.
(5). Clean again and again until cloth stays

clean.
(6). Apply masking tape around repair area

and on data plate.
9B63-038A
(7). Dry main rotor static mast in air for a Figure 801. Static Mast
minimum of 15 minutes before you
apply primer. C. Main Rotor Static Mast Inner
surfacePitting Corrosion Repair
(Ref. CSPSPM)
Item Nomenclature
(8). Apply primer (C308)to repair area of C308 Primer
static mast. Dry film thickness of C313 Paint Stripper
0.0006-0.0010 in. (0.015-0.025 mm)
C432 Cleaner
(Ref. CSP-SPM, Section 20-30-00).
C802 Cloth, NonLint
(9). Dry in air for a minimum of one hour C807 Sandpaper
before you apply finish enamel.
Page 803
(1). Remove main rotor drive shaft. (a). Remove pitting, use sandpaper
(C807) or finer. Move sandpaper
parallel to mast center line and not
CAUTION radially.
Do not permit paint stripper or unwanted (b). Solvent wipe with cleaner (C432)and
material to go down inner or outer sur a non-lint cloth (C802).
faces of mast below repair.
(c). Visually examine repair area to make
Do not permit paint stripper or unwanted sure pit(s) are removed, use a bright
material to go into transmission. Damage light and minimum of10x magnifica
to transmission can occur. tion.
Speak to an MDHI Field Service Repre
(d). Inner dimension of static mast can
sentative if unwanted materials go into
not be than 3.769 in. (95.733 mm).
transmission.
If inner dimension is more than
permitted, speak to an MDHI Field
Paint Stripper (C313)
Service Representative.
NOTE:
Cadmium plating must be done as speci
(2). Remove primer from inner surface of mum thickness 0.0003 in. (0.3 mil).
main rotor static mast where there is Cadmium plating must be applied by an
pitting corrosion, use paint stripper individual or service center that is ap
(C313) (Ref. CSP-SPM). Remove paint proved by the equipment manufacturer
stripper with moist cloth, do not scrub for the brush plating procedure.
area and do not flush. You must use an approved low embrittle
ment solution for all brush plating proce
Cleaner (C432)
dures.
(6). Touch up cadmium plating, use a brush
on procedure.
(7). Clean area with cleaner (C432) and a
(3). Clean main rotor static mast repair non-lint cloth (C802). Clean surface
area with cleaner (C432) and a non-lint with another clean cloth before solvent
cloth (C802). evaporates.
Do not use a mechanical grinder (8). Clean again and again until cloth stays
CAUTION to remove corrosion. It can clean.
cause too much heat in repair areas. (9). Dry main rotor static mast in air for a
minimum of 15 minutes before you
NOTE: Make measurement before and after apply primer.
material removal.
Primer (C308)
(4). Measure mast inner dimension.
Dimension permitted is 3.749-3.769 in.
(95.225-95.733 mm).
(5). If after pitting removed, dimension will (10). Apply primer (C308) to repair area of
not be more than 3.769 in. (95.733 static mast. Dry film thickness of
mm), do the steps that follow: 0.0006-0.0010 in. (0.015-0.025 mm)
(Ref. CSP-SPM, Section 20-30-00).
NOTE: Make pits smooth on an area 10 times
the dimension of the depth dimension. (11). Dry in air for a minimum of one hour.
Page 804
(12). Install main rotor hub (Ref. Section (14). Do the Main Rotor Drive Plate Nut
62-20-00) Torque Verification (Ref. Special
Inspection - After Component Installa
tion Section 05-20-10 and Section
(13). Install main rotor drive shaft. 63-10-00).
MAXIMUM ALLOWABLE ID AFTER REPAIR

3.769 INCH (95.7326 MM)
ID REPAIR
AREA.
9G63-044
Figure 802. Main Rotor Support Static Mast Pitting Repair
Page 805
D. Main Rotor Mast BasePaint Repair Primer (C308)
C308 Primer
(4). Apply primer (C308) to mast base. Dry
film thickness of 0.0006-0.0010 in.
Consumable Materials (0.015-0.025 mm) (Ref. CSP-SPM,
(Ref. CSPSPM) Section 20-30-00).
Item Nomenclature
(5). Dry in air for a minimum of one hour
before you apply finish enamel.
(1). Recommended Method - Remove
mast support base. Finish Enamel, White (C302)
(2). Alternative Method - Get access to

mast support base as follows:
(6). Apply white finish enamel (C302) to
(a). Remove main rotor hub (Ref. primed areas of mast mast. Dry film
62-20-00). thickness of 0.0017-0.0025 in.
(0.043-0.064 mm) (Ref. CSP-SPM,
(b). Remove swashplate (Ref. 62-30-00). Section 20-30-00).
(7). Dry in air for a minimum of eight
(c). Remove mixer links (Ref. 62-30-00). hours.
(8). Apply white finish enamel (C302) to the
NOTE: Make sure all non-repair areas of heli primed areas to dry film thickness of
copter have protection from chemicals and 0.0017 to 0.0025 inch (0.043 to 0.063
paint spray. mm) Ref. CSP-SPM, Section
20-30-00).
(3). Examine main rotor support static (9). Install mast support base or compo
mast for corrosion (Ref. Main rotor nents removed to get access to mast
Static Mast Inspection). support base.
Page 806
Chapter
ANTI-TORQUE ASSEMBLY
TABLE OF CONTENTS
64-30-00 NOTARr Anti-Torque Fan System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A

1. Anti-Torque System Fan Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Anti-Torque Fan Assembly Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Figure 1.Anti-Torque Fan Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1. NOTAR Anti-Torque Fan System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
A. Removal of the Anti-Torque Fan System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
B. Installation of the Anti-Torque Fan System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
Figure 401.Anti-Torque Fan System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 402
Figure 402.Anti-Torque Fan Assembly (Sheet 1 of 2) . . . . . . . . . . . . . . . . . . . . . . . 404
C. Anti-Torque Fan Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 406
D. Anti-Torque Fan Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 406
E. Counterweight Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 408
F. Counterweight Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 408
Figure 403.Pitch Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 409
2. NOTAR Fan Pitch Assembly (Pitch Control) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 409
A. Disassembly of the Pitch Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 409
B. Assembly of the Pitch Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 409
Figure 404.Anti-Torque Fan Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 412
3. Anti-Torque Fan Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 413
A. Anti-Torque Fan Support Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 413
B. Anti-Torque Fan Support Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 413
C. Anti-Torque Fan Support Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 413
D. Anti-Torque Fan Support Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 414
4. Magnetic Motional Pickup Transducer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 414
A. Removal of Pickup Transducer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 414
B. Installation of Pickup Transducer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 415
5. Velocimeter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 415
A. Removal of Velocimeter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 415
B. Installation of Velocimeter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 415
6. NOTAR Fan Felt Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 416
A. Felt Seal Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 416
B. Felt Seal Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 416
Figure 405.Felt Seal Machining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 417
C. Felt Seal Machining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 417
Page i

Inspection/Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601
1. Anti-Torque Fan System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601
A. Anti-Torque Fan System Inspection (Area 6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601
B. Anti-Torque Fan Component Inspection (Area 6) . . . . . . . . . . . . . . . . . . . . . . . . . . . 601
Table 601.Fan Pitch Plate Damage Limits (Ref. Figure 402) . . . . . . . . . . . . . . . . 602
Table 602.Fan Blade Damage Limits (Ref. Figure 601) . . . . . . . . . . . . . . . . . . . . . 602
Figure 601.Fan Blade Damage Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 604
Table 603.Fan Hub Damage Limits (Ref. Figure 602) . . . . . . . . . . . . . . . . . . . . . . 605
Figure 602.Fan Hub Damage Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 606
C. Pitch Control Inspection (Area 6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 607
D. Anti-Torque Fan Support Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 607
E. Anti-Torque Fan Liner (Felt Metal Seal) Inspection . . . . . . . . . . . . . . . . . . . . . . . . 607
F. Tension-Torsion Strap Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 608
Figure 603.Tension-Torsion Strap Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 609
Repair/Modification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 801
1. Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 801
A. Anti-Torque Fan Balance Weight Rivet Stud Replacement . . . . . . . . . . . . . . . . . . 801
Figure 801.Rivet Stud Replacement (Typical) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 802
2. Modification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 803
A. Anti-Torque Fan Assembly Upgrade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 803
Table 801.Anti-Torque Fan Assembly Configuration Conversions . . . . . . . . . . . 803
Table 802.Anti-Torque Fan Modification Criteria . . . . . . . . . . . . . . . . . . . . . . . . . 803
Page ii
Section
643000
NOTAR
AntiTorque Fan
System
NOTAR ANTITORQUE FAN SYSTEM

1. AntiTorque System Fan Assembly Fan Blades - Each blade is comprised of an
aluminum alloy forged spar and polypropylene
injection molded blade. The pitch horns are
(Ref. Figure 1)
aluminum alloy and hard anodized to mini
mize wear and corrosion. Attaching washers to
The NOTAR anti-torque fan is an axial fan the counterweight arms on the spar of the
with thirteen variable pitch blades. The fan blade, and positioning of index marked
provides anti-torque by furnishing variable counter-weights, overcome pedal forces from
flow of low pressure high volume air through the fan. The counter-weight index marks are
the tailboom and thrusters. The fan operation factory set and adjustment is not allowed.
al rpm in flight at 100% power is 5,412 rpm.
At 104% power, the fan rpm is 5,628. Fan Liner - The fan liner felt metal seal
provides a controlled gap between the fan and
The NOTAR System is designed to be a the felt metal seal for optimum efficiency of
failsafe system. Complete stoppage of the fan the fan during flight.
will not prevent a safe autorotational landing.
A spring loaded limit capsule in the control Balance Studs - There are thirteen balance
input to the fan retains vertical stabilizer fin studs equally spaced around the fan hub.
control and prevents any fan failure from Balancing of the fan is accomplished, with the
locking the remaining controls. The ability to fan installed in the aircraft, by adding or
control the vertical stabilizer fins provides subtracting balance washers to the thirteen
adequate anti-torque for a safe landing. balance studs.
2. AntiTorque Fan Assembly Components Pitch Plate - A sliding pitch plate uniformly
changes the angle of the blades through the
pitch horns which are part of the blade spar.
Fan Hub - The fan hub is an aluminum alloy The pitch plate is aluminum alloy and
forging centered on an angular contact mounted to a stainless steel shaft which slides
double-row ball bearing that reacts to changes inside the hub support shaft. As the pitch plate
to thrust in both directions. slides with the shaft, it actuates each blade
pitch horn to control the blades. Replaceable
Center Spline Assembly - The center spline cuff bushings are at each pitch horn/pitch
assembly attaches to the fan hub with thirteen plate interface to minimize the effects of wear.
bolts and nuts. These bolts also attach the The pitch plate rotates with the blades about a
inboard end of the tension-torsion straps to double row ball pitch bearing.
the spline/hub assembly. The spline assembly
also provides the spline drive surfaces to mate Pitch Control - Pitch control is applied to the
with the fan support driveshaft. pitch plate by a stationary control rod end
through a double row ball bearing. This allows
Tension-Torsion Straps - Tension-torsion the transition from stationary to rotating pitch
straps attach the blades to the hub. The straps control.
react to blade centrifugal forces while provid
ing a torsional spring counteracting blade Interrupter - A steel pin is installed at one
pitch forces. The tension-torsion strap is location on the forward face of the fan hub.
comprised of a continuous Kevlar filament This pin acts as a magnetic field interrupter
wound around a Corrosion Resistance Steel for the azimuth sensor used by the aircraft
Alloy (CRES) spool type bushing at each end. installed balancing equipment.
Page 1
64-30-00 Original
FAN PITCH
CONTROL ASSY
FAN LINER
FAN HUB
TENSIONTORSION
STRAPS
BLADE ASSY
9G64001
Figure 1. AntiTorque Fan Assembly
Page 2
Original 64-30-00
NOTARR ANTITORQUE FAN SYSTEM

1. NOTARr AntiTorque Fan System (8). Remove lockwasher (12) from support
shaft (11).
A. Removal of the AntiTorque Fan System
(a). Release tangs from locknut (13).
(Ref. Figure 401)
(b). Pull lockwasher (12) from shaft (11).
Special Tools
(Ref. CSPSPM) (c). Discard lockwasher (12).
Item Nomenclature
Do not leave fan on support
T603 AntiTorque Shaft Socket CAUTION shaft without locknut. Fan can
slip off support shaft and cause damage to
Do the Anti-Torque/Directional helicopter or injury to personnel.
CAUTION Controls Travel/Rigging Verifi
cation procedure after you do maintenance NOTE: If helicopter does not have a rotor
on anti-torque controls (ref. Section brake, you must have the aid of one more
67-20-00). person. Manually hold main rotor hub so fan
does not turn while lock nut is being re
(1). Put WARNING in cockpit that flight moved.
controls are disconnected.
(9). Apply rotor brake (if installed) (ref.
(2). Remove baggage compartment soft applicable Rotorcraft Flight Manual,
insulation roof panels (ref. Section refer to Section 01-00-00, Table 201).
25-50-00).
(10). Remove locknut (13) with anti-torque
(3). Remove lower center diffuser F7 and shaft socket (T603).
lower access panel F8 (ref. Section
53-30-00). (11). Remove fan (9).
(4). Remove pitch assembly (ref. Section (12). If necessary, disengage rotor brake.
64-30-03).
B. Installation of the AntiTorque Fan
(5). Measure and record clearance between System
fan blade tips to felt seal.
(Ref. Figure 401)
(a). Clearance must be 0.030 to 0.065
inch (0.76 to 1.65 mm).
(6). Measure and record clearance between (Ref. CSPSPM)
each fan blade and hub. Item Nomenclature
(a). If clearance of a blade is more than C702 Lockwire
the average clearance of other blades
by more than 0.10 inch (2.5 mm),
remove and inspect the torsion-ten Special Tools
sion strap for that blade (ref. Section (Ref. CSPSPM)
65-30-00, Inspection Test). Item Nomenclature
(7). Remove upper center diffuser assembly T603 AntiTorque Shaft Socket
F6 (ref. Section 53-30-00).
Page 401
10
8
5
4
3
6 5
2
1
12 7
11
13
9G64-003B
1. FAN CONTROL SHAFT ASSY 8. BOLT
2. PITCH ASSY 9. FAN
4. NUT 11. FAN SUPPORT SHAFT
5. WASHER 12. LOCKWASHER
6. BOLT 13. LOCKNUT
7. ROD END BEARING
Figure 401. AntiTorque Fan System
Do not leave fan on support (1). Apply rotor brake (if installed) (ref.
CAUTION shaft without locknut. Fan can applicable Rotorcraft Flight Manual
slip off support shaft and cause damage to refer to Section 01-00-00, Table 201).
helicopter or injury to personnel.
(2). Put fan on fan support shaft with pitch
plate aft.
NOTE: If helicopter does not have a rotor (3). Align fan splines with fan support shaft
brake, you must have the aid of one more splines and push forward.
person. Manually hold main rotor hub so fan
does not turn while lock nut is being remo (4). Install locknut on fan support shaft,
ved. with anti-torque shaft socket (T603).
Page 402
(a). Torque locknut 70 to 80 ft-lb (94.9 (14). Align clevis of pitch control rod with
to 108.5 Nm). pitch control assembly rod end bearing.
(5). Align tabs of new lockwasher with (15). Install bolt, washers, and nut. Torque
notches of locknut and install on fan nut and install cotter pin.
support shaft. (16). Turn rotor system and listen for
unusual noises. None permitted.
(6). Push lockwasher forward over locknut.
(17). Make sure there is clearance of 0.020
(7). Make sure two tabs of lockwasher go to 0.040 inch (0.51 to 1.02 mm)
through notches of lock nut and engage between fan interrupter and azimuth
forward side of lock nut. sensor. If necessary adjust azimuth
sensor.
(8). If necessary, disengage rotor brake.
(18). Remove WARNING from cockpit that
(9). Make sure fan blade tips to fan liner flight controls are disconnected.
clearance is 0.030 to 0.065 inch (0.76
to 1.65 mm). (19). Do the Anti-Torque/Directional
Controls Travel/Rigging Verification
(10). Install upper center diffuser F6 (ref. procedure (ref. Section 67-20-00).
Section 53-30-00). (20). Install access panels F7 and F8 (ref.
Section 53-30-00).
(11). Put pitch control assembly in fan
support shaft, align bolt holes. (21). Do the Fan Balance Procedure (ref.
Section 18-00-00).
(12). Install bolts and washers. Torque bolts.
(22). Install baggage compartment soft
(13). Safety bolts in pairs, use lockwire insulation roof panels (ref. Section
(C702). 25-50-00).
Page 403
10
25
6 REF
12
13
7 REF 24 11
26 15
16
VIEW ROTATED
22
1
6 5
13 17
4
21 14
9 7
20
3
23
2 18
19
9G64-002-1A
Figure 402. AntiTorque Fan Assembly (Sheet 1 of 2)
Page 404
1 REF
5 REF
APPLY SEALANT TO
THIS EDGE ONLY
15 REF
DO NOT PERMIT SEALANT
ON THIS SURFACE
14 REF
16 REF
FILLET SEAL
VIEW ROTATED
CURE DATE
LORD R
SHELTON CT.USA 11/04
EXPIRATION DATE 11/09
EXAMPLE OF INK MARK DATE

9G64-002-2A
1. FAN HUB 14. BOLT

2. COTTER PIN 15. CENTER SPLINE BUSHING
3. WASHER 16. CENTER SPLINE
4. BLADE SPAR (PART OF BLADE ASSEMBLY) 17. INNER RIM BUSHING
5. TENSIONTORSION STRAP 18. BALANCE STUD
6. COUNTERWEIGHT 19. LOCKING COLLAR
7. SET SCREW 20. WASHER
8. PIN 21. NUT
9. BLADE 22. COLLAR
10. PITCH PLATE 23. PIN
11. PITCH PLATE BUSHING 24. SLEEVE
12. NUT 25. BLADE INDEX MARK
13. FLAT WASHER 26. COUNTERWEIGHT INDEX MARK
Figure 402. AntiTorque Fan Assembly (Sheet 2 of 2)
Page 405
C. AntiTorque Fan Disassembly (c). Install nut and washer. Torque nut.
If stud locking collar is loose, replace
(Ref. Figure 402) collar and stud (ref. Anti-Torque Fan
Balance Weight Rivet Stud Replace
(1). Remove anti-torque fan assembly. ment.
NOTE: If you will assemble fan with same D. AntiTorque Fan Assembly
blades and tension-torsion straps, mark (Ref. Figure 402)
their locations in hub before disassembly.
Use a soft tip felt pen.
(2). Remove nuts (12), washers (13), and (Ref. CSPSPM)
bolts (14). Item Nomenclature
(3). Pull blades (9) out to disconnect C226 Sealing and Locking Compound
tension-torsion straps (5) from center C228 Sealant Primer
spline (16) and disengage pitch horns
C308 Primer
from pitch plate (10).
C310 Primer
NOTE: Center spline is installed with wet seal C827 Desiccant
ant.
(4). Remove pitch plate (10) and center NOTE: If hub is not replaced, and interrupter
spline (16). pin or balance studs are not defective, go to
Step (4).
(5). Turn each blade sufficiently to remove (1). Install fan balance interrupter pin (23).
cotter pin (2) and washer (3).
(a). Point fan hub (1) inner rim down.
(6). Remove pins (8) and tension-torsion
straps (5).
NOTE: Rivet hole where pin is installed is lo
cated 4.125 inch (104.78 mm) from center
(7). Carefully remove blades (9), move of hub.
counterweight arms through openings (b). Remove all burrs and clean rivet hole
in outer rim of hub (1). in hub.
(8). Remove bushings (17). NOTE: If you use a waterborne primer, do not
thin with water Use acetone (C436).
(9). Remove sleeve (24).
Primer (C308)
NOTE:
Do not change balance stud and washers
unless they are defective, or a fan compo
nent is replacement. (c). Apply a thin layer of primer (C308)
There is one installation washer on each to rivet hole.
balance stud. All other washers are for NOTE: Install pin while primer is still wet.
fan balance.
(d). Install pin (23).
(10). If a fan blade is replaced and more than
one washer is installed on its related (e). Tap head of pin with a non-metallic
balance stud (18), do the procedure that hammer until pin is fully installed.
follows: (f). Install collar (22).
(a). Remove nut (21) and washer (20). (2). If removed, install balance stud(s) (ref.
Anti-Torque Fan Balance Weight Rivet
(b). Remove balance washer(s). Stud Replacement).
Page 406
Do not tighten nuts on studs too NOTE: If you can not seal package; put, ten
CAUTION much. If you tighten nut too sion-torsion strap, package, and desiccant
much, balance stud locking collar can be (C827) in new plastic bag.
come loose during subsequent nut removal.
(b). Put tension-torsion strap in package
(3). Install one washer (20) and nut (21) on and seal package openings with tape.
each balance stud. Torque nuts. (c). Put package in box and seal box with
tape.
(4). Point fan hub (1) open side up.
(11). If tension-torsion strap(s) is new, do
(5). Push bushings (17) in each of thirteen the steps that follow:
1.370 in. (34.80 mm) diameter holes in (a). Remove tension-torsion strap from
inner rim of hub (1). Make sure bushing package and write the word EX
flanges are on inner side of rim. PIRATION DATE on the strap face
and date five years after the package
(6). Install sleeves (24) in outer rim of hub is opened, use permanent ink.
(1).
(b). Make an item component record card
NOTE: If a fan blade is replaced, transfer coun for each tension-torsion strap.
terweights from old blade to new blade.
NOTE: Install tension-torsion straps so that
the cure date is in view when fan is as
(7). If necessary, install counterweights (ref.
sembled.
counterweight removal/installation).
(12). Put large bushing end of tension-tor
Center spline bolts have the sion strap in blade spar.
WARNING same life limit as the fan
hub. Because these bolts do not have (13). Align holes in blade spar and tension-
serial numbers, their lives must be the torsion strap. Install pin.
same as the fan hub they were first (14). Turn blade sufficiently to install washer
installed in, and must be replaced and cotter pin.
when the hub is replaced.
(15). Turn blade to 20 mark on fan hub. Pull
(8). Carefully install blades, move counter blade out until counterweight arms are
weight arms through sleeves in outer against outer rim of hub.
rim of hub and blade spars through
NOTE: Replace center spline bushings if loose,
inner rim bushings.
damaged, or missing.
(9). Align blade index mark with 20 mark (16). If installation of center spline bushing
on fan hub. is necessary, do the procedure that
follows:
NOTE:
Primer (C310)
Tension-torsion straps have a life limit
that starts when their package is opened.
Tension-torsion straps can be put back in
their package, and life limit not started, if
not out of the package more than five (a). Apply primer (C310) to outside
days. diameter of center spline bushing.
(b). While primer is still wet, press
(10). If tension-torsion strap is removed bushing into 0.375 inch (9.53 mm)
from package for no more than five diameter hole of center spline.
days, do the steps that follow:
NOTE: If you install a new 900R2441007-101
(a). Replace desiccant in package, use center spline, you must also replace support
desiccant (C827). shaft and fan shaft coupling.
Page 407
Sealing Compound (C213) (a). Torque nuts 75 to 100 in-lb (8.47 to

11.30 Nm).
(24). Apply a 0.1 inch (2.54 mm) fillet of
sealing compound (C213) to joint
between hub and center spline.
(17). 900R1441005-101, 900R1441005-103,
and 900R1441005-105 fan only - E. Counterweight Removal
Apply a thin layer of sealing compound
(C213) to edge of center spline as (Ref. Figure 402)
shown. Do not permit sealing compound (1). Apply heat to loosen set screw (7).
on surface shown.
(2). Remove set screw (7) and discard.
(a). While sealant is still wet, put center
spline, with bushing side up, in (3). Remove counterweight (6).
center of hub. Align center spline and
hub bolt holes. F. Counterweight Installation
(18). Put center spline, with bushing side up, (Ref. Figure 402)
in center of hub. Align center spline and
hub bolt holes. Consumable Materials
(Ref. CSPSPM)
(19). Hold pitch plate above fan and align Item Nomenclature
pitch plate bushings with blade pitch
horns.
C228 Sealant Primer
(20). Move blades in to engage blade pitch
horns with pitch plate bushings align
tension-torsion strap bolt holes with Sealant Primer (C228)
holes in center spline.
Sealant Primer (C228)
(1). Apply sealant primer (C228) to new set

screw. Dry primer fully.
(2). Put counterweight in pitch horn of
(21). Apply a thin coat of sealant primer blade.
(C228) to the threads only of bolts
(NO TAG). Dry primer fully. NOTE: Make sure counterweight and pitch
horn index marks are correctly aligned. All
NOTE: Be careful when you install bolts, Do counterweights are aligned the same.
not push bushings out of center spline.
(3). Align index mark on counterweight
(22). Install bolts and washers through hub, with index mark on pitch horn.
center spline, and tension-torsion
straps.

(C226) to threads of set screw and
install in pitch horn.
(C226) to bolt threads. Install washers (a). Torque set screw 4 to 6 in-lb (0.45
and nuts. to 0.68 Nm).
Page 408
1. NUT 6. INNER RETAINER

2. BOLT 7. HOUSING
3. WASHER 8. ROD END BEARING
4. OUTER RETAINER 9. LOCKWASHER
5. BEARING 10. SLIDER
Figure 403. Pitch Control
2. NOTARr Fan Pitch Assembly (Pitch B. Assembly of the Pitch Control
Control)
(Ref. Figure 403)
(Ref. Figure 403)
A. Disassembly of the Pitch Control
(Ref. CSPSPM)
(1). Remove pitch control (ref. Procedure Item Nomenclature
1.C.). C308 Primer
C436 Acetone
(2). Measure and make a record of dimen
C702 Lockwire
sion between outer retainer (4) and
center of rod end bearing (8).
(1). Lubricate bearing (5) as necessary (ref.
(3). Remove lockwire (C702) from nut (1) Section 12-00-00).
and bolts (2).
If a new bearing (5) is installed,
(a). Discard lockwire (C702). CAUTION make sure the part number and
serial number of the bearing are recorded in
NOTE: Bolts (2), outer retainer (4), and slider the Rotorcraft Log Book.
(10) are installed with wet primer.
(2). Assemble rod end bearing (8), nut (1),
(4). Remove bolts (2), washers (3), and lockwasher (9), bearing (5), and
outer retainer (4) with bearing (5) and retainers (4, 6).
inner retainer (6).
(3). Adjust rod end bearing (8), with the
NOTE: Inner retainer (6) has threads and func dimension recorded during disassembly,
tions as a castellated nut. from outer retainer (4) to center of rod
end bearing (8).
(5). Loosen nut (1).
(a). Torque nut (1) (ref. CSP-SPM,
(6). Remove rod end bearing (8), nut (1), Section 20-10-00).
and lockwasher (9).
(b). Safety nut (1) to lockwasher (9) with
(7). Remove slider (10). lockwire (C702).
Page 409
If you use a water-based prim (6). Apply primer (C308) to bolts (2).
CAUTION er, do not thin it with water. Use
acetone (C436) to thin the primer. (a). Install bolts (2) and washers (3)
while primer (C308) is still wet.
(4). Apply primer (C308) to the mating
surfaces of housing (7) and slider (10).
(b). Torque bolts (2) (ref. CSP-SPM,
(a). Install slider (10) in housing (7) while Section 20-10-00).
primer (C308) is still wet.
(c). Safety bolts (2) to outer retainer (4)
(5). Apply primer (C308) to mating surface
of housing (7) and outer retainer (4).
(a). Install outer retainer (4) in housing (7). Install pitch control (ref. Procedure
(7) while primer (C308) is still wet. 1.D.).
Page 410
Page 411
20
3
2
18
21
19 20
15
16
14 19
17
5 6 7
4
6
12
8
13 12
9
11
10
9G64-005A
1. FAN SUPPORT ASSEMBLY 12. LABYRINTH SEAL
2. BRACKET WITH AZIMUTH SENSOR 13. SUPPORT HOUSING
3. BRACKET WITH VIBRATION SENSOR 14. FAN SHAFT COUPLING
4. COTTER PIN 15. NUT
5. NUT 16. LOCK WASHER
6. WASHER 17. SHIM
7. BOLT 18. AZIMUTH SENSOR
8. BEARING RETAINER 19. NUT
9. SUPPORT SHAFT 20. WASHER
10. BEARING 21. VIBRATION SENSOR
11. BEARING REMOVAL RING
Figure 404. AntiTorque Fan Assembly
Page 412
3. AntiTorque Fan Support (15). Remove fan support (1).

(Ref. Figure 404) B. AntiTorque Fan Support Disassembly
(1). Remove bearing retainer (8).
Special Tools
(Ref. CSPSPM) (2). Remove support shaft (9) with bearing
Item Nomenclature (10), and bearing removal ring (11).
T603 AntiTorque Shaft Socket (3). Remove bearing (10) and bearing
removal ring (11).
A. AntiTorque Fan Support Removal (4). Remove labyrinth seals (12).
(1). Remove anti-torque fan. C. AntiTorque Fan Support Assembly
(2). Remove fan driveshaft (ref. Section
(Ref. CSPSPM)
(3). Remove and discard lock washer (16). Item Nomenclature
C111 Oil
(4). Remove nut (15), use anti-torque shaft
socket (T603). C702 Lockwire
(5). Remove fan shaft coupling (14) and

shim (17). (1). Push labyrinth seals in bevelled side of
retainer and support housing.
(6). Disconnect Electrical Connector P434.
NOTE: If bearing is replaced, record part and
(7). Disconnect Electrical Connector P433. serial number of in rotorcraft log book.
Different types of grease can be
(8). EARLY CONFIG - Remove cotter pin CAUTION necessary for different bearing
(4), nut (5), washer (6), and azimuth
sensor bracket (2). part numbers.
(9). EARLY CONFIG - Remove washer (6) (2). Lubricate bearing as necessary (ref.
and bolt (7). Section 12-00-00).
Oil (C111)
(10). CURRENT CONFIG - Remove cotter
pin (4), nut (5), and washer (6) at
azimuth sensor bracket (2).
(11). CURRENT CONFIG - Remove
bracket (2), washer (6), and bolt (7). (3). Apply a thin layer of oil (C111) to
support shaft.
(12). Remove cotter pin (4), nut (5), washer
(6), and vibration sensor bracket (3). (4). Install bearing removal ring and
bearing on support shaft.
(13). Remove washer (6) and bolt (7).
(5). Push support bearing on shaft so
NOTE: Bolt at top location is shorter than other bearing is tight against ring.
two bolts.
NOTE: If you install a new 900R2441007-101
Fan support can fall out of sup center spline (ref. 64-30-01), you must also
CAUTION port frame when you remove replace 900R2441002-101 support shaft
bolts. Hold fan support when you remove (ref. 64-30-02) and 900R2444002-101 fan
last bolt. shaft coupling.
(14). Remove cotter pin (4), nut (5), washers (6). Install support shaft, bearing removal
(6), and bolt (7) from top location. ring, and bearing into support housing.
Page 413
(7). Install bearing retainer on shaft and NOTE: If you install a new 900R2441007-101
align retainer and housing bolt holes. center spline (ref. Section 64-30-01), you
must also replace 900R2441002-101 sup
(8). Install anti-torque fan support. port shaft (ref. Section 64-30-02) and
900R2444002-101 fan shaft coupling.
D. AntiTorque Fan Support Installation
(11). Install fan shaft coupling and lock nut
(1). Install fan support in support frame with anti-torque shaft socket (T603).
and align bolt holes. Torque lock nut 70 to 80 ft-lb (94.92
to 108.48 Nm).
NOTE: (12). Connect anti-torque drive shaft to
Do not torque nuts until all nuts are transmission (Ref. Section 63-10-00).
installed.
(13). Install two bolts in fan shaft coupling,
Bolt at top location is shorter than other do not tighten bolts.
two bolts.
(14). Measure clearance between coupling
(2). Install top bolt, washers, and nut. and anti-torque drive shaft. Clearance
must be 0.001 to 0.010 inch (0.03 to
NOTE: 0.25 mm).
EARLY CONFIG - 900R2445005-101 NOTE: Shim laminates are 0.003 inch (0.08
azimuth sensor bracket is installed on aft mm) thick.
side of fan support frame.
(15). Remove layers from shim to get
CURRENT CONFIG - necessary thickness.
900R2445005-103 azimuth sensor brack
et is installed on forward side of bearing (16). Remove two bolts from anti-torque
retainer. drive shaft at coupling.
(17). Remove anti-torque drive shaft (ref.
(3). Install bolt, washer, azimuth sensor Section 63-10-00).
and bracket, washer, and nut at lower
right hole of support frame. (18). Remove lock nut, use anti-torque shaft
socket (T603).
(4). Install bolt, washer, vibration sensor
and bracket, washer, and nut at lower (19). Remove coupling.
left hole of support frame. (20). Install shim, coupling, and lock nut
with anti-torque shaft socket (T603).
(5). Torque nuts and install cotter pins. Torque lock nut 70 to 80 ft-lb (94.92
to 108.48 Nm).
(6). Connect electrical connector P434 to
vibration sensor. (21). Install new lock washer.
(7). Connect electrical connector P433 to (22). Install fan driveshaft (ref. Section
azimuth sensor. 63-10-00).
4. Magnetic Motional Pickup Transducer
(8). Safety azimuth sensor and vibration
sensor electrical connectors with A. Removal of Pickup Transducer
lockwire (C702).
(1). Remove right half of anti-torque fan
(9). Install anti-torque fan. center body (ref. Section 53-30-00).
(2). Remove and discard lockwire from
(10). Make sure clearance between fan electrical connector P433, transducer
balance interrupter pin and azimuth (18), bracket (2), and nuts (19).
sensor is 0.020 to 0.040 inch (0.51 to
1.02 mm). (3). Disconnect electrical connector P433.
Page 414
(4). Remove nut (19), washer (20), azimuth 5. Velocimeter

sensor (18), washer (20), and nut (19).
A. Removal of Velocimeter
B. Installation of Pickup Transducer
(Ref. Figure 404)
Consumable Materials (1). Remove left half of anti-torque fan
(Ref. CSPSPM) center body (ref. Section 53-30-00).
Item Nomenclature
(2). Remove and discard lockwire from
C702 Lockwire electrical connector P434, velocimeter
(21), and bracket (3).
NOTE: If this is the first installation of an (3). Disconnect electrical connector P434.
MHS5284 transducer, you must change the
electrical connector to MS3456W10SL-4S, (4). Remove velocimeter (21).
the electrical connector backshell to
MHS5842WR1002L, the bracket to B. Installation of Velocimeter
900R2445005-103, and get two
(Ref. Figure 404)
NAS1423C10 nuts. Discard nut that comes
on transducer.
(1). Install nut, washer, transducer, washer, (Ref. CSPSPM)
and nut. Item Nomenclature
NOTE: Do not tighten nuts at this time. C702 Lockwire
(2). Adjust clearance between fan balance

interrupter pin and transducer to 0.020 (1). Install velocimeter (21) in bracket (3).
to 0.040 inch (0.51 to 1.02 mm).
(a). Torque velocimeter (21) 40 to 45
(3). Torque nuts 40 to 45 in-lb (4.5 to 5.1 in-lb (4.5 to 5.1 Nm).
Nm).
(b). Safety velocimeter (21) with lockwire
(4). Safety nuts with lockwire (C702). (C702).
(5). Connect electrical connector P433 to (2). Connect electrical connector P434 to
transducer. velocimeter (21).
(a). Safety with lockwire (C702). (a). Safety with lockwire (C702).
(6). Install right half of anti-torque fan (3). Install left half of anti-torque fan
center body (ref. Section 53-30-00). center body (ref. Section 53-30-00).
Page 415
6. NOTARR Fan Felt Seal Sealing Compound (C234)
A. Felt Seal Removal
NOTE: After removal, felt seal will not be ser

viceable. (1). Apply sealing compound (C234) to
faying surfaces of felt seal and struc
ture.
(1). Remove fan assembly.
(2). Install felt seal with larger counterbore
(2). Remove sealant around edges of felt rivet hole forward (nearest to fan
seal a plastic scraper. support strut).
(3). While sealing compound (C234) is still
(3). Remove rivets that attach felt seal to wet, install rivets that attach felt seal
helicopter structure. to structure.
(4). Put inner tube (T601) in felt seal and
(4). Pull felt seal away from mating surface
inflate sufficiently to hold felt seal
and remove from helicopter.
against structure.
B. Felt Seal Installation (5). After sealing compound (C234) has
cured, remove inner tube (T601).
Consumable Materials Sealing Compound (C211)

(Ref. CSPSPM)
Item Nomenclature
C211 Sealing Compound, Corrosion Inhibitive (6). Mask and fill all joints, rivet holes, and
fan liner edges with sealing compound
(C211).
Special Tools (7). Remove mask while sealant is still
(Ref. CSPSPM) tacky and smooth to match fan liner
Item Nomenclature contour.
T601 Inner Tube (8). After sealant has fully cured, do felt
seal machining procedure.
Page 416

11
2 21 (3 PL) 20 (3 PL)
20 (3 PL)

3 19 (3 PL)

4
1 REF

10 15 REF
7

16 REF
1
15 6
18

16 12
7

FAN LINER
AFTER MACHINING
FAN LINER
BEFORE MACHINING
22

17
13 (2 PL)
14 (2 PL)
CROSS SECTION VIEW
23 (2 PL)
9G64-008A
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. FAN SUPPORT 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 405. Felt Seal Machining
C. Felt Seal Machining (2). Remove anti-torque fan support
assembly.
(Ref. Figure 405)
NOTE: Felt metal material can cause FOD con
tamination.
Special Tools
(Ref. CSPSPM) (3). Apply masking tape and plastic sheet to
Item Nomenclature baggage compartment, fan duct, and
T602 Fan Tip Seal Tool fan diffuser areas.
Use only cutter and equipment

NOTE: Do this procedure only after a new felt CAUTION supplied with fan tip seal tool
seal is installed. (T602).
(1). Remove anti-torque fan driveshaft (ref. NOTE: Make sure fan tip seal tool (T602) is
Section 63-10-00). clean before you install it.
Page 417
(4). Install pin (5) in fan support (6). (22). Make sure there is no radial or axial
movement in tool (1).
(5). Install bolts (19), washers (20), and
nuts (21). (23). Lubricate tool motor with pneumatic
tool oil.
(a). Torque nuts.
Eye protection, a respirator,
(6). Put cutter (3) in motor collet (4). Do not WARNING gloves, and protective cloth
tighten collet. ing must be worn during felt seal ma
chining.
(7). Apply a thin film of oil to inner side of
pin (5) and outer side of tool (1) shaft. (24). Loosen position lock knob (15) and turn
adjustment knob (16) to position cutter
(8). Put tool (1) in pin (5) and push forward. (3) for a cut of not more than one fourth
width of cutter (3).
(9). Turn tool (1) by hand and adjust cutter
(3) to highest point on felt seal. (a). Tighten position lock knob (15).
(a). Tighten collet (4). (25). Connect speed handle (17) to tool (12).
(10). Remove tool (1). (26). Connect pneumatic pressure source to

tool (12).
(11). Remove thrust bearing (7) from tool (1) (27). Turn valve (18) to adjust tool speed.
shaft.
(28). Turn tool (1) counterclockwise at a
(12). Put calibration arm (2) on tool (1). moderate to slow rate. Do not force cut.
(13). Measure dimension between cutter (3) (29). After one full turn, again loosen
and stop on calibration arm (2). position lock knob (15) and turn
adjustment knob (16) to position cutter
(14). Put thrust bearing (7) on tool (1) shaft. (3) for a cut of not more than one fourth
(15). Loosen motor collet (4) and move cutter width of cutter (3).
(3) out 0.040 to 0.050 inch (1.02 to (a). Tighten position lock knob (15).
1.27 mm) or until cutter touches stop
on calibration arm (2). (30). Do Step (29). again and again until felt
seal is fully machined.
(a). Tighten collet.
(31). Disconnect pneumatic pressure source
(16). Loosen position lock knob (15) and turn to tool (12).
adjustment knob (16) until cutter (3) is
(32). Disconnect speed handle.
at aft most position.
(33). Remove cap screws, washers, and
(a). Tighten position lock knob (15). spacers.
(17). Put thrust bearing (7) on tool (1) shaft. (34). Remove ball lock pin and tool (12).
(18). Put tool (1) in pin (5) and push forward. (35). Remove threaded knob, nylon washer,
thrust bearing retainer, thrust bearing,
(19). Install spacer (8), thrust bearing (7), and spacer.
thrust bearing retainer (10), nylon
washer (9), and threaded knob (11). (36). Remove tool (1).
(a). Tighten threaded knob (11). (37). Remove thrust bearing from tool shaft.
(20). Put tool (12) on tool (1) and install ball (38). In Step (15)., did cutter (3) touch the
stop on calibration arm (2)?
lock pin (22).
(a). No, go to Step (12).
(21). Install cap screws (13), washers (14),
and spacers (23). Torque cap screws. (b). Yes, go to Step (39).
Page 418
(39). Remove nuts, washers, and bolts. (42). Install support assembly.
Remove pin.
(43). Install diaphragm NOTAR shaft
(40). Clean baggage compartment, fan duct assembly (ref. Section 63-10-00).
and diffuser areas.
(44). Install fan assembly.
(41). Remove masking tape and plastic
sheet. (45). Install pitch assembly.
Page 419
Page 420

INSPECTION/TEST
1. AntiTorque Fan System (4). Tension-torsion strap bushings for
cracks and wear. None permitted.
A. AntiTorque Fan System Inspection
(Area 6) (5). Attach pin for wear and corrosion.
(1). Remove lower center diffuser F7 and Polish to remove scratches and corro
lower access panel F8 (Ref. Section sion, minimum pin diameter 0.311 in.
53-30-00). (7.90 mm).
(2). Make sure blade tips to felt metal tip (6). Hub inner rim bushings for cracks and
seal clearance is a minimum of 0.030 wear. None permitted.
in. (0.762 mm). Maximum clearance
0.065 in. (1.651 mm). (7). Center spline for cracks. No cracks
permitted.
(3). Turn main rotor. Listen for unusual
noises. (8). Center spline for wear and corrosion.
No wear or corrosion permitted in
(4). Measure clearance between fan blades female splines or twenty-six attach
and hub. If clearance for a blade is holes. All other areas, make damage
more than the average clearance of smooth, maximum depth 0.005 in.
other blades by more than 0.10 in. (0.127mm) maximum area 0.010 sq in.
(2.54 mm), replace that torsion-tension (12.9 sq mm). No limit on quantity of
strap and blade. separate areas of damage.
(5). Make sure there is a clearance of
0.020-0.040 in. (0.50-1.02 mm) (9). Center spline hub for loose, cracked, or
between fan interrupter and azimuth worn bushings. None permitted.
sensor. If necessary, adjust azimuth
(10). Blades for cracks, nicks, scratches,
sensor.
erosion, impact damage, bulges, or
(6). Install lower center diffuser F7 and blisters.
lower access panel F8 (Ref. Section
53-30-00). (11). Pitch horns for loose counterweights. If
loose, do the Pitch Horn Counterweight
B. AntiTorque Fan Component Inspection Set Screw Replacement.
(Area 6)
(12). Pitch horn for too much wear (not
round). None permitted.
(Ref. Table 601, Table 602, and Table 603)
(13). Fan hub for cracks. None permitted.
NOTE: If you think a part is unserviceable,
speak to MDHI Field Service Department (14). Fan hub for scratches, nicks, and
for more instructions. gouges.
Examine anti-torque fan components as (15). Fan hub for loose or damaged balance
follows: studs. None permitted.
(1). Pitch plate for cracks, wear, and
(16). Fan hub for loose or damaged magnetic
corrosion.
interrupter. None permitted.
(2). Pitch plate bushings for wear, grooves
or cracks. None permitted. (17). Hub sleeves for missing segment. None
permitted.
(3). Tension-torsion straps for nicks or cuts
where kevlar fibers show. None per (a). If sleeve is replaced, examine hole in
mitted. hub for wear. No wear permitted.
Page 601
Table 601. Fan Pitch Plate Damage Limits (Ref. Figure 402)
Maximum Maximum
Pitch plate for scratches, Maximum damage Maximum material Make damage smooth,
nicks, and missing permitted, 0.020 in. (0.51 removal, 0.020 in. (0.51 use 240 grit abrasive cloth
material. mm) in depth or 0.020 sq. mm). (C810) (or finer). Remove
in. (12.9 sq. mm) in area. surface defects or sharp
Minimum distance edges. Touch up surface
between damage, 0.25 in. finish with alodine (C241)
(6.35 mm). No more than and primer (C308).
three locations of damage
permitted in each sq. in.
Table 602. Fan Blade Damage Limits (Ref. Figure 601)

Maximum Maximum
Fan blades for cracks. None permitted.
Area A Damage permitted in one Maximum material Make damage smooth
fan blade leading edge for location, maximum removal, 0.020 in. (0.51 with 240 grit abrasive
nicks and damage. dimension and location as mm) depth and 0.040 in. cloth (C810) (or finer).
shown. (1.02 mm) by 0.25 in. Remove damaged
(6.35 mm) in area. material or sharp edges.
Area B Damage permitted within Maximum material Make damage smooth
fan blade outboard trailing specified limits in location removal, 0.020 in. (0.51 with 240 grit abrasive
edge for damage and shown. mm). cloth (C810) (or finer).
missing material. Remove damaged
material or sharp edges.
Area C Damage permitted within Maximum material Make damage smooth
fan blade inboard trailing specified limits in location removal, 0.020 in. (0.51 with 240 grit abrasive
edge for damage and shown. mm). cloth (C810) (or finer).
missing material. Remove damaged
material or sharp edges.
Area D Maximum damage Maximum material Make damage smooth
fan blade cuff for nicks permitted on flange, 0.020 removal, 0.020 in. (0.51 with 240 grit abrasive
and missing material. in. (0.51 mm) in depth or mm). cloth (C810) (or finer).
0.004 sq. in. (2.58 sq. Remove sharp edges and
mm) in area. Minimum surface defects.
distance between
damage, 0.50 in. (12.7
mm) along the circumfer-
ence. No damage
permitted on inboard and
outboard flat surfaces.
Page 602
Table 602. Fan Blade Damage Limits (Ref. Figure 601) (Cont.)
Maximum Maximum
Area E Maximum damage Maximum material Make damage smooth,
fan blade spar cylinder for permitted, 0.015 in. (0.38 removal, 0.015 in. (0.38 use 240 grit abrasive cloth
scratches, nicks, and mm) in depth or 0.020 sq. mm). (C810) (or finer). Remove
missing material. in. (12.9 sq. mm) in area. surface defects or sharp
Area F Minimum thichness of the Maximum material Make damage smooth,

fan blade counterweight constant area between removal, 0.015 in. (0.38 use 240 grit abrasive cloth
arms for scratches, nicks counterweight and mm). (C810) (or finer). Remove
and missing material. cylinder, 0.190 in. (4.83 surface defects or sharp
mm). Maximum damage edges. Touch up surface
permitted, 0.015 in. (0.38 finish with alodine (C241)
mm) in depth or 0.015 sq. and primer (C308).
in. (9.68 sq. mm) in area.
No more than three
locations of damage
permitted in each arm.
Area G One location of damage is Maximum material Make damage smooth,

fan blade spar arms for permitted. Maximum removal, 0.020 in. (0.51 use 240 grit abrasive cloth
scratches, nicks, and damage permitted, 0.020 mm). (C810) (or finer). Remove
missing material. in. (0.51 mm) in depth surface defects or sharp
and 0.004 sq. in. (2.58 edges. Touch up surface
sq. mm) in area. finish with alodine (C241)
and primer (C308).
Area H Damage permitted within Material can not be Make damage smooth,
fan blade outer tip surface specified limits in location removed from area B. use a file and then 240 grit
for scratches, nicks, shown. Remove other damage at abrasive cloth (C810) (or
missing material, and a 45 degree angle. finer). Remove sharp
damage. Minimum blade thichness edges and surface
at outer tip, 0.050 in. defects.
(1.27 mm). A smooth
groove less than 0.040 in.
(1.016 mm) in depth and
0.250 in. (6.35 mm) wide
is permitted. The groove
must not go to edge of fan
blade.
Area J Damage permitted within Maximum surface defect, Lightly clean crack with
fan blade forward and aft specified limits in location 1.0 in. (25.4 mm) in scouring pad (C817) and
surfaces for defects and shown. length or 0.03 in. (0.76 seal cyanoacrylate
cracks. mm) in height. Maximum adhesive (C442).
crack length, 0.75 in.
(19.1 mm).
Page 603

0.5 IN.
2.5 IN
(12.7 mm)

(6.35 cm)
0.06 IN.
(1.52 mm)

B 0.125 IN.
(3.18 mm)

3.0 IN. A
(7.62 cm) 0.30 IN.

(7.62 mm)

0.06 IN. C
(1.52 mm) G
0.050 (1.27mm)

J D
0.30 IN.
MINIMUM (7.62 mm)
E
REPAIR SURFACE
-45 ANGLE
VIEW LOOKING UP
VIEW LOOKING DOWN
NOTE:
IGNORE TOOL MARKS AND PLASTIC FLOW INDICATIONS THAT ARE IN THE MOLDED PART OF THE FAN BLADE. THESE
ARE NOT AN INDICATION OF DEFECTS OR DAMAGE. 9G64-009D
Figure 601. Fan Blade Damage Limits
Page 604
Table 603. Fan Hub Damage Limits (Ref. Figure 602)

Maximum Maximum
Area A Maximum damage Maximum material Make damage smooth,
fan hub outboard blade permitted, 0.010 in. (0.25 removal, 0.010 in. (0.25 use a file and then 240 grit
contact surface for mm) in depth or 0.005 sq. mm). abrasive cloth (C810) (or
scratches, nicks, and in. (3.23 sq. mm) in area. finer). Remove sharp
missing material. Minimum distance edges and surface
between damage, 1 in. defects. Touch up chromic
(25.4 mm). anodize.
Area B Maximum damage Maximum material Make damage smooth,
fan hub outboard flange permitted, 0.010 in. (0.25 removal, 0.010 in. (0.25 use 240 grit abrasive cloth
for scratches, nicks, and mm) in depth or 0.010 sq. mm). (C810) (or finer). Remove
missing material. in. (6.45 sq. mm) in area. surface defects or sharp
(12.7mm). No more than and primer (C308).
Area C Maximum damage Maximum material Make damage smooth,
fan hub flange for permitted, 0.050 in. (1.27 removal, 0.050 in. (1.27 use 240 grit abrasive cloth
scratches, nicks, and mm) in depth. No more mm). (C810) (or finer). Remove
missing material. than three locations of surface defects or sharp
damage permitted in each edges. Touch up surface
sq. in. finish with alodine (C241)
and primer (C308).
Areas other than A,B,&C Maximum damage Maximum material Make damage smooth,
Fan hub for scratches, permitted, 0.020 in. (0.51 removal, 0.020 in. (0.51 use 240 grit abrasive cloth
nicks, and missing mm) in depth or 0.015 sq. mm). (C810) (or finer). Remove
material. in. (9.68 sq. mm) in area. surface defects or sharp
Page 605
B C
B
C
9G64-011
Figure 602. Fan Hub Damage Limits
Page 606
C. Pitch Control Inspection (Area 6) axial or radial play is 0.002 in.

(0.05mm).
(Ref. Figure 403)
D. AntiTorque Fan Support Inspection
speak to MDHI Field Service Department (Ref. Figure 404)
for more instructions.
Examine pitch control components as follows: speak to MDHI Field Service Department
for more instructions.
(1). Housing (7) for serviceable threaded
inserts, cracks, nicks, scratches, and (1). Examine support shaft for:
corrosion. Cracks or loose threaded (a). Cracks. None permitted.
inserts are not permitted. Nicks,
scratches, and surface corrosion, can be (b). Scores from bearing installation or
removed and made smooth Maximum removal. None permitted.
material removal, 0.005 in. (0.127mm)
depth and 0.010 sq. in. (12.9 sq. mm) (c). Damaged splines. None permitted.
in area. No limit on quantity of sepa (2). Examine fan support bearing for:
rate areas of damage.
(a). Spalls and pits on balls. None
(2). Slider (10) for cracks, nicks, scratches, permitted.
and corrosion. No cracks permitted.
TFE bearing surface can be worn to a (b). Heat damage (blue color). None
minimum outer diameter of 0.817 in. permitted.
(20.75 mm). No nicks, scratches, or (c). Corrosion on balls and races. None
corrosion in TFE surface or inner bore
permitted.
permitted. All other areas can have
damage made smooth. Maximum (d). Free movement of set. Replace
material removal, 0.005 in. (0.127mm) bearing set if movement is rough or it
depth and 0.010 sq. in. (12.9 sq. mm) does not move freely.
in area. No limit on quantity of sepa
rate areas of damage. (3). Examine fan support bearing retainer
and housing for:
(3). Outer retainer (4) for cracks, nicks,
scratches, and corrosion. No cracks (a). Cracks. None permitted.
permitted. No nicks, scratches, or (b). Scores from bearing installation or
corrosion permitted in the three attach removal. None permitted.
holes. All other areas can have damage
made smooth. Maximum material (4). Examine bearing labyrinth seal for
removal, 0.005 in. (0.127mm) depth tears and deterioration. None per
and 0.010 sq. in. (12.9 sq. mm) in mitted.
area. No limit on quantity of separate
areas of damage. (5). Examine hub shim for cracks and wear.
No cracks permitted.
(4). Inner retainer (6) for cracks, nicks,
scratches, and corrosion. None per E. AntiTorque Fan Liner (Felt Metal Seal)
mitted. Inspection
(5). Bearing (5) for smooth operation, speak to MDHI Field Service Department
corrosion, and indication of too much for more instructions.
heat. No defects permitted.
(1). Examine for cracks and loose liner
(6). Rod end bearing (8) for radial and axial material.
play, corrosion, and indication of grease
leakage. No corrosion or indication of (2). Examine for cracks around the radius
grease leakage permitted. Maximum of cutouts for fan support.
Page 607
(3). Examine for cracks in felt metal seal (4). X-ray inspection must be done at an
material. None permitted. x-ray laboratory.
F. TensionTorsion Strap Inspection (a). X-rays inspection must be done and

interpreted by a level II or higher
(Ref. Figure 603) x-ray technician.
(b). Do an x-ray inspection of all straps.
(1). Remove anti-torque fan.
NOTE: If a defect is found during the x-ray in
(2). Disassemble anti-torque fan, and spection, turn strap and do the inspection
remove tension-torsion straps. again to make sure the indication is correct.
(3). Examine tension-torsion straps for the (5). Examine all areas of strap on x-ray
defects that follow: film for progressive fiber fractures.
Carefully examine very important
(a). Nicks or cuts where kevlar fibers areas. None permitted.
show. None permitted. (6). Replace unserviceable straps, and
reassemble anti-torque fan.
(b). Strap bushings for cracks and wear.
None permitted. (7). Install anti-torque fan.
Page 608
KV 80
MA 8
TIME 25 SECONDS
FFD 48 INCHES
FILM D2 OR EQUIVALENT
SCREENS NONE
DENSITY IN VERY
IMPORTANT AREAS 1.80 to 2.25 H & D
SHOTS 0 AND 90 DEGREES
RADIATION SOURCE
0 DEGREES
VERY IMPORTANT AREA

VERY IMPORTANT AREA
RADIATION SOURCE
CURE DATE
XX - XX
S/N XXX-XXX 90 DEGREES

XXXXXXXXXX
SERIAL NUMBER PART NUMBER

PROGRESSIVE FIBER
FRACTURE
PROGRESSIVE
FIBER
FRACTURE
90 DEGREES VIEW X-RAY 0 DEGREES VIEW 9G64-017A

(VERY IMPORTANT AREAS)
Figure 603. TensionTorsion Strap Inspection
Page 609
Page 610

REPAIR/MODIFICATION
1. Repair NOTE: Install rivet stud while epoxy is still
wet.
NOTE: For allowable repairs; (4). Install pin rivet stud.
Ref. Table 602 for fan blade assembly.
Ref. Table 603 for fan hub. (a). Insert rivet stud (3) into prepared
Ref. Table 601 for fan pitch plate. hole.
A. AntiTorque Fan Balance Weight Rivet (b). Gently tap head of rivet stud with a
Stud Replacement non-metallic hammer to fully seat
rivet stud.
(Ref. Figure 801) NOTE: Collars shall not be reused. Collars
shall be replaced with the same part num
ber as the original installation.
(Ref. CSPSPM) (5). Install new collar.
Item Nomenclature
(a). Thread collar (4) onto pin rivet stud.
C310 Primer
(b). Place box-end wrench over wrench
ing device of collar.
(c). Insert hex wrench into hex cavity at
(1). Remove nut (1) and washer (2) from pin top of rivet stud.
rivet stud (3).
(d). Hold rivet stud stationary and
tighten collar onto rivet stud until
(2). Remove stud (3) and collar (4) from hub
wrenching device shears from collar.
(5) with hex wrench and locking pliers.
Primer (C310)
(3). Prepare hub for balance rivet stud
installation.
(a). Remove all chips, burrs and foreign

material from rivet holes of hub. (e). Touch up sheared area of collar with
primer (C310).
Adhesive, Epoxy (C402) Do not over-torque the nuts on
CAUTION the balancing studs. An over-
torqued nut may cause the stud's locking
collar to become loose the next time the nut
is removed.
(b). Lightly coat holes with epoxy adhes (6). Install washer (2) and nut (1) on stud.
ive (C402). Torque nut.
Page 801
64-30-00 Original
9G64004
1. NUT
2. BALANCE WASHER
3. PIN RIVET STUD
4. LOCKING COLLAR
5. FAN HUB
Figure 801. Rivet Stud Replacement (Typical)
Page 802
Original 64-30-00
2. Modification (2). Anti-Torque fan part number

900R1441002-109 may be upgraded to
A. AntiTorque Fan Assembly Upgrade 900R1441005-101 by replacing the
900R2441013-107 Hub with a
(Ref. Table 801 and Table 802) 900R2441013-105 Hub.
(3). Anti-Torque fan part number
NOTE: The following tables describe the fan 900R1441005-101 may be upgraded to
components that need to be changed to up 900R1441005-103 by replacing the
grade early configuration fan assemblies to 500N5311-5 tension torsion strap with
later or current configurations. 900R3442009-101 tension torsion
strap.
(1). Anti-Torque fan part number
900R1441002-113 may be upgraded to (4). Anti-Torque fan part number
900R1441002-109 by replacing the 900R1441005-103 may be upgraded to
900R2441007-101 Spline and 900R1441005-105 by replacing the
900R2442012-105 Blade Assy. with a 900R2441013-105 hub with a
900R2441016-101 Spline and 900R2441013-109 hub and adding
900R2442012-103 Blade Assy. 900R2441017-101 sleeves
Table 801. AntiTorque Fan Assembly Configuration Conversions

Modification Required
Configuration From To (Item No.Table 802 )
900R1441002113 900R1441002109 1
900R1441002109 900R1441005101 2
900R1441005101 900R1441005103 3
900R1441005103 900R1441005105 4
NOTE: Configuration upgrades are not mandatory.
Table 802. AntiTorque Fan Modification Criteria

Item
No. Quantity Parts to be Removed Parts to be Installed
1 1 900R2441007101 Spline 900R2441016101 Spline
900R2442012105 Blade Assembly 900R2442012103 Blade Assembly
2 1 900R2441013107 Hub 900R2441013105 Hub
3 13 500N53115 TensionTorsion Strap 900R3442009101
4 1 900R2441013105 Hub 900R2441013109 Hub and add
900R2441017101 Sleeves
900R2441007101 or
900R2441016101 Spline
900R3442009101 (set of 13) or
900R3442009103 (set of 13) tension
torsion straps
NOTE: 900R3442009-103 and 900R6442009-103 Tension Torsion Straps are two-way inter
changeable with each other and can be used in any combination with each other.

64-30-00 Original
Chapter
FLIGHT CONTROLS
TABLE OF CONTENTS
67-00-00 Flight Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A

1. Flight Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Cyclic Controls Subsystem . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
A. Cyclic Stick Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
B. Copilot (Quick Release) Cyclic Stick . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
C. Cyclic Stick Centering Device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
D. Cyclic Stick Base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
E. Longitudinal and Lateral Trim Actuators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
F. Longitudinal and Lateral Linkages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
G. Longitudinal Controls Balance Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
H. Longitudinal and Lateral Hydraulic Servoactuators . . . . . . . . . . . . . . . . . . . . . . . . 3
Figure 1.Cyclic Controls Subsystem (Sheet 1 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3. Collective Controls Subsystem . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
A. Collective Stick Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
B. Copilot (Quick Release) Collective Stick . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
C. Collective Friction Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
D. Collective Friction Release Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
E. Collective Linkages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
F. Collective Controls Balance Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
G. Collective Servoactuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Figure 2.Collective Controls (Dual) Subsystem (Sheet 1 of 2) . . . . . . . . . . . . . . . . 8
4. Anti-Torque/Directional Controls Subsystem . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
A. Anti-Torque/Directional Pedal Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
B. Anti-Torque/Directional Linkages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
C. Anti-Torque/Directional Servoactuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
D. Splitter Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
E. NOTAR Fan Linkages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
F. Direct Jet Thruster Linkages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Figure 3.Anti-Torque/Directional Controls Subsystem (Sheet 1 of 3) . . . . . . . . . 12
5. Vertical Stabilization Control Subsystem (VSCS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
A. Collective Control Position Transducer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
B. Right Linear Lateral Accelerometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
C. VSCS Yaw Rate Gyros . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
D. VSCS Control Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
E. VSCS Linear Actuators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Page i

F. Endplate Spar Tube Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
G. Upper and Lower Horizontal Endplates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
H. VSCS Position Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Figure 4.VSCS Control Subsystem . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Fault Isolation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
1. Rotor Flight Controls System Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Table 101.Main Rotor Flight Control System Troubleshooting . . . . . . . . . . . . . . 101
2. Anti-Torque/Directional Flight Controls Troubleshooting . . . . . . . . . . . . . . . . . . . . . . 104
Table 102.Anti-Torque/Directional Flight Control System Troubleshooting . . 104
67-10-00 Rotor Flight Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A
1. Collective Stick Boot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
A. Collective Stick Boot Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
B. Collective Stick Boot Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
2. Collective Control Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
A. Collective Control Module Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
B. Collective Control Module Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
3. Pilot Collective Control Stick Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
A. Pilot Collective Control Stick Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
B. Pilot Collective Control Stick Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . 402
4. Collective Friction Unit Link Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 403
A. Collective Friction Unit Link Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . 403
B. Collective Friction Unit Link Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . 403
5. Collective Friction Unit Arm Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 403
A. Collective Friction Unit Arm Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . 403
B. Collective Friction Unit Arm Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . 403
6. Collective Friction Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 404
A. Collective Friction Unit Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 404
B. Collective Friction Unit Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 404
Figure 401.Collective Stick and Collective Friction Installation . . . . . . . . . . . . . . 405
7. Collective Stick Link Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 406
A. Collective Stick Link Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 406
B. Collective Stick Link Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 406
8. Collective Cockpit Control Tube Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 406
A. Collective Cockpit Control Tube Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . 406
B. Collective Cockpit Control Tube Assembly Installation . . . . . . . . . . . . . . . . . . . . . . 406
Page ii

9. Collective Stick Bellcrank Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 407
A. Collective Stick Bellcrank Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 407
B. Collective Stick Bellcrank Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 407
10. Collective Stick Bracket Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 407
A. Collective Stick Bracket Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 407
B. Collective Stick Bracket Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 407
11. Collective Closet Control Tube Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 407
A. Collective Closet Control Tube Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . 407
B. Collective Closet Control Tube Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . 408
12. Collective Controls Balance Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 408
A. Collective Controls Balance Spring Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 408
B. Collective Controls Balance Spring Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 408
13. Collective Position Sensor Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 409
A. Collective Position Sensor Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 409
B. Collective Position Sensor Assembly Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . 409
C. Collective Position Sensor Assembly Reassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . 409
D. Collective Position Sensor Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 410
14. Collective Lower Closet Bellcrank Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 411
A. Collective Lower Closet Bellcrank Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . 411
B. Collective Lower Closet Bellcrank Assembly Installation . . . . . . . . . . . . . . . . . . . . 411
15. Collective Lower Closet Bellcrank Bracket Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 411
A. Collective Lower Closet Bellcrank Bracket Assembly Removal . . . . . . . . . . . . . . . 411
B. Collective Lower Closet Bellcrank Bracket Assembly Installation . . . . . . . . . . . . 411
Figure 402.Pilot Collective Controls, Cockpit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 412
16. Copilot (Quick Release) Collective Control Stick (900 CONFIG) . . . . . . . . . . . . . . . . 413
A. Copilot (Quick Release) Collective Control Stick (900 CONFIG) Removal . . . . . 413
B. Copilot (Quick Release) Collective Control Stick (900 CONFIG) Installation . . 413
17. Copilot Collective Control Stick Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 414
A. Copilot Collective Control Stick Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . 414
B. Copilot Collective Control Stick Assembly Installation . . . . . . . . . . . . . . . . . . . . . . 414
18. Deleted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 414
19. Copilot (Quick Release) Collective Control Stick (902 CONFIG) . . . . . . . . . . . . . . . . 415
A. Copilot (Quick Release) Collective Control Stick (902 CONFIG) Removal . . . . . 415
B. Copilot (Quick Release) Collective Control Stick (902 CONFIG) Installation . . 415
20. Interconnect Cable Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 415
A. Interconnect Cable Assemblies Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 415
Page iii

B. Interconnect Cable Assemblies Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 415
21. Collective Interconnect Control Rod Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 416
A. Collective Interconnect Control Rod Assembly Removal . . . . . . . . . . . . . . . . . . . . . 416
B. Collective Interconnect Control Rod Assembly Installation . . . . . . . . . . . . . . . . . . 416
22. Copilot Collective Link Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 416
A. Copilot Collective Link Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 416
B. Copilot Collective Link Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 416
23. Collective Bellcrank Assembly, Copilot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 416
A. Copilot Collective Bellcrank Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 416
B. Copilot Collective Bellcrank Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . 416
24. Collective Stick Bracket Assembly, Copilot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 417
A. Copilot Collective Stick Bracket Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . 417
B. Copilot Collective Stick Bracket Assembly Installation . . . . . . . . . . . . . . . . . . . . . . 417
Figure 403.Copilot Collective Controls, Cockpit (Sheet 1 of 2) . . . . . . . . . . . . . . . 418
25. FS 157.730 Collective Bellcrank Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 420
A. Collective Bellcrank Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 420
B. Collective Bellcrank Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 420
26. Collective (Cabin) Control Rod Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 420
A. Collective (Cabin) Control Rod Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . 420
B. Collective (Cabin) Control Rod Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . 420
27. Collective Upper Deck Bellcrank Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 420
A. Collective Upper Deck Bellcrank Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . 420
B. Collective Upper Deck Bellcrank Assembly Installation . . . . . . . . . . . . . . . . . . . . . 421
28. Collective Bracket Assembly - FS 170.877 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 421
A. Collective Bracket Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 421
B. Collective Bracket Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 421
29. Collective To Actuator Control Rod Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 421
A. Collective To Actuator Control Rod Assembly Removal . . . . . . . . . . . . . . . . . . . . . . 421
B. Collective To Actuator Control Rod Assembly Installation . . . . . . . . . . . . . . . . . . . 421
Figure 404.Collective Controls, Upper Deck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 422
30. Cyclic Stick Boot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 422
A. Cyclic Stick Boot Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 422
B. Cyclic Stick Boot Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 422
31. Cyclic Stick Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 423
A. Cyclic Stick Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 423
B. Cyclic Stick Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 423
Page iv

32. Copilot (Quick Release) Cyclic Stick Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 423
A. Copilot (Quick Release) Cyclic Stick Assembly Removal . . . . . . . . . . . . . . . . . . . . . 423
B. Copilot (Quick Release) Cyclic Stick Assembly Installation . . . . . . . . . . . . . . . . . . 424
33. Pilot Cyclic Stick Centering Strap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 424
A. Pilot Cyclic Stick Centering Strap Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 424
B. Pilot Cyclic Stick Centering Strap Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 424
Figure 405.Cyclic Stick Assembly (Sheet 1 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 425
34. Cyclic Base Lateral Control Tube Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 428
A. Cyclic Base Lateral Control Tube Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . 428
B. Cyclic Base Lateral Control Tube Assembly Installation . . . . . . . . . . . . . . . . . . . . 428
35. Lateral Dual Control Interconnect Control Rod Assembly . . . . . . . . . . . . . . . . . . . . . 428
A. Lateral Interconnect Control Rod Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . 428
B. Lateral Interconnect Control Rod Assembly Installation . . . . . . . . . . . . . . . . . . . . 428
36. Pilot Cyclic Base Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 428
A. Pilot Cyclic Base Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 428
B. Cyclic Base Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 429
C. Cyclic Base Reassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 429
D. Pilot Cyclic Base Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 429
Figure 406.Cyclic Base Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 430
37. Lateral Bellcrank Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 431
A. Lateral Bellcrank Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 431
B. Lateral Bellcrank Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 431
38. Lateral Bracket Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 431
A. Lateral Bracket Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 431
B. Lateral Bracket Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 431
39. Lateral Gradient Spring Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 431
A. Lateral Gradient Spring Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 431
B. Lateral Gradient Spring Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 431
40. Lateral Trim Actuator Crank Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 431
A. Lateral Trim Actuator Crank Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . 431
B. Lateral Trim Actuator Crank Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . 432
41. Lateral Trim Actuator Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 432
A. Trim Actuator Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 432
B. Trim Actuator Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 432
42. Lateral Lower Closet Bellcrank Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 432
A. Lateral Lower Closet Bellcrank Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . 432
Page v

B. Lateral Lower Closet Bellcrank Assembly Installation . . . . . . . . . . . . . . . . . . . . . . 432
43. Lateral Lower Closet Bellcrank Bracket Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 433
A. Lateral Lower Closet Bracket Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . 433
B. Lateral Lower Closet Bracket Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . 433
44. Lateral Closet Control Rod Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 433
A. Lateral Control Rod Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 433
B. Lateral Control Rod Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 433
Figure 407.Cockpit Lateral Cyclic Controls (Sheet 1 of 2) . . . . . . . . . . . . . . . . . . . 434
45. Upper Closet Lateral Bellcrank Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 436
A. Upper Closet Lateral Bellcrank Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . 436
B. Upper Closet Lateral Bellcrank Assembly Installation . . . . . . . . . . . . . . . . . . . . . . 436
46. Lateral Deck Control Rod Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 436
A. Lateral Deck Control Rod Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 436
B. Lateral Deck Control Rod Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 436
47. FS 165.588 Lateral Bellcrank Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 437
48. FS 165.588 Lateral Bracket Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 437
Figure 408.Upper Deck Lateral Cyclic Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . 438
49. Lateral Control Link Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 438
A. Lateral Control Link Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 438
B. Lateral Control Link Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 438
50. FS 170.536 Lateral Bellcrank Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 439
51. Lateral Actuator Control Rod Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 439
A. Lateral Actuator Control Rod Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . 439
B. Lateral Actuator Control Rod Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . 439
52. FS 170.536 Lateral Bracket Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 440
Figure 409.Upper Deck Lateral Servoactuator Controls . . . . . . . . . . . . . . . . . . . . 440
53. Longitudinal Trim Actuator Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 441
A. Trim Actuator Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 441
B. Trim Actuator Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 441
Page vi

54. Longitudinal Trim Actuator Crank Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 441
A. Longitudinal Trim Actuator Crank Assembly Removal . . . . . . . . . . . . . . . . . . . . . . 441
B. Longitudinal Trim Actuator Crank Assembly Installation . . . . . . . . . . . . . . . . . . . 441
55. Longitudinal Gradient Spring Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 442
A. Longitudinal Gradient Spring Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 442
B. Longitudinal Gradient Spring Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 442
56. FS 144.775 Longitudinal Bellcrank Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 442
A. Longitudinal Bellcrank Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 442
B. Longitudinal Bellcrank Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 442
58. FS 150.064 Longitudinal Bracket Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 443
A. Longitudinal Bracket Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 443
B. Longitudinal Bracket Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 443
60. FS 132.900 Longitudinal Control Rod Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 444
A. Longitudinal Control Rod Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 444
B. Longitudinal Control Rod Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 444
61. Longitudinal Aft-Cockpit Control Rod Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 445
A. Longitudinal Aft-Cockpit Control Rod Assembly Removal . . . . . . . . . . . . . . . . . . . 445
B. Longitudinal Aft-Cockpit Control Rod Assembly Installation . . . . . . . . . . . . . . . . 445
62. Longitudinal Closet Control Rod Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 445
A. Longitudinal Closet Control Rod Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . 445
B. Longitudinal Closet Control Rod Assembly Installation . . . . . . . . . . . . . . . . . . . . . 445
63. Extension Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 446
A. Extension Spring Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 446
B. Extension Spring Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 446
64. Balance Spring Clip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 446
A. Balance Spring Clip Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 446
B. Balance Spring Clip Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 446
65. Longitudinal Interconnect Control Rod Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 447
A. Longitudinal Interconnect Control Rod Assembly Removal . . . . . . . . . . . . . . . . . . 447
B. Longitudinal Interconnect Control Rod Assembly Installation . . . . . . . . . . . . . . . 447
Page vii

Figure 410.Cockpit Longitudinal Cyclic Controls (Sheet 1 of 2) . . . . . . . . . . . . . . 448
69. FS 157.387 Longitudinal Control Rod Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 450
A. Longitudinal Control Rod Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 450
B. Longitudinal Control Rod Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 450
72. Longitudinal To Actuator Control Rod Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 452
A. Longitudinal To Actuator Control Rod Assembly Removal . . . . . . . . . . . . . . . . . . . 452
B. Longitudinal To Actuator Control Rod Assembly Installation . . . . . . . . . . . . . . . . 452
Figure 411.Upper Deck Longitudinal Cyclic Controls . . . . . . . . . . . . . . . . . . . . . . . 453
73. Control Deck Bracket Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 454
A. Control Deck Bracket Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 454
B. Control Deck Bracket Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 454
74. FS 155.500 FOD Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 454
A. FOD Cover Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 454
B. FOD Cover Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 454
75. FOD Cover - Collective/Longitudinal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 455
A. FOD Cover - Collective/Longitudinal Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 455
B. FOD Cover - Collective/Longitudinal Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 455
76. Lateral FOD Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 456
A. Lateral FOD Cover Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 456
B. Lateral FOD Cover Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 456
77. Drip Pan Assembly, RH and LH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 457
Page viii

A. Drip Pan Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 457
B. Drip Pan Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 457
78. Control Rod Boot, Upper Deck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 457
A. Control Rod Boot Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 457
B. Control Rod Boot Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 458
79. Tailstock Boot, Upper Deck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 459
A. Tailstock Boot Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 459
B. Tailstock Boot Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 459
80. Dual Hydraulic Actuator Unit, Rotor Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 459
A. Dual Hydraulic Actuator Unit Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 459
B. Dual Hydraulic Actuator Unit Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 459
81. Boosted System Bracket Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 460
A. Boosted System Bracket Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 460
B. Boosted System Bracket Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 460
Figure 412.Upper Deck FOD Covers, Boots and Actuators . . . . . . . . . . . . . . . . . . 461
Inspection/Test/Rigging Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601
1. Rotor Flight Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601
A. Rotor Flight Control System Inspection (Area 1) . . . . . . . . . . . . . . . . . . . . . . . . . . . 601
B. Rotor Flight Control System Inspection (Area 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . 602
C. Rotor Flight Control System Inspection (Area 3) . . . . . . . . . . . . . . . . . . . . . . . . . . . 603
D. Rotor Flight Control System Operational Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 603
E. Cyclic Stick In Center Position Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 605
Figure 601.Cyclic Stick In Center Position Procedure . . . . . . . . . . . . . . . . . . . . . . . 605
F. Rotor Servoactuator Functional Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 606
Figure 602.Rotor Servoactuator Functional Test Schematic . . . . . . . . . . . . . . . . . 607
G. Rotor Flight Controls Travel Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 608
H. Rotor Flight Controls Rigging Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 609
2. Rotor Flight Controls System Rigging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 610
A. Prepare Rotor Flight Controls System For Rigging . . . . . . . . . . . . . . . . . . . . . . . . . 610
B. Collective Controls System Rigging (Lower) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 610
C. Cyclic Trim Actuator Rigging (Longitudinal And Lateral) . . . . . . . . . . . . . . . . . . . 612
D. Longitudinal Cyclic Control System Rigging (Lower) . . . . . . . . . . . . . . . . . . . . . . . . 613
E. Lateral Cyclic Control System Rigging (Lower) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 614
Figure 603.Rotor Flight Controls (Lower) (Sheet 1 of 2) . . . . . . . . . . . . . . . . . . . . . 616
F. Collective Controls Mixer Rigging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 618
Figure 604.Collective Controls Mixer Rigging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 620
G. Longitudinal Cyclic Mixer Rigging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 621
Page ix

H. Lateral Cyclic Mixer Rigging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 623
Figure 605.Cyclic Mixer Rigging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 625
3. Cyclic Trim Actuator Resistor Value . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 626
Figure 606.Resistor Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 627
4. Trim Actuator P/N 900C3010004-107 Electronic Stop Test . . . . . . . . . . . . . . . . . . . . 628
Figure 607.Forward Interconnect Panel (A612) Terminal Board 3 . . . . . . . . . . . 629
67-10-20 Collective Control Module/Cyclic Grip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A
Fault Isolation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Table 101.Collective Control Module/Cyclic Grip Troubleshooting . . . . . . . . . . . 101
Figure 101.Cyclic Grip Switch Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
Figure 102.Collective Control Module Switch Wiring (Sheet 1 of 3) . . . . . . . . . . 103
1. Collective Control Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
A. Collective Control Module Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
B. Collective Control Module Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
C. Collective Control Module Reassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
D. Collective Control Module Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
Figure 401.Collective Control Module Installation . . . . . . . . . . . . . . . . . . . . . . . . . 402
Figure 402.Collective Control Module Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 402
2. Cyclic Grip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 403
A. Cyclic Grip Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 403
B. Cyclic Grip Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 403
C. Cyclic Grip Reassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 403
D. Cyclic Grip Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 403
3. Wire Harness - W135, Cyclic Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 403
A. Wire Harness - W135, Cyclic Controls Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 403
B. Wire Harness - W135, Cyclic Controls Installation . . . . . . . . . . . . . . . . . . . . . . . . . 404
Figure 403.Cyclic Grip Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 405
Figure 404.Cyclic Grip Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 406
67-20-00 Anti-Torque/Directional Flight Controls . . . . . . . . . . . . . . . . . . . . . . . . . . A
1. Heel Rest Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
A. Heel Rest Assemblies Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
B. Heel Rest Assemblies Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
2. Directional Control Pedals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
A. Directional Control Pedals Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
Page x

B. Directional Control Pedals Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
3. Pedal Adjustment Handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
A. Pedal Adjustment Handle Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
B. Pedal Adjustment Handle Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
4. Pedal Adjustment Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
A. Pedal Adjustment Pin Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
B. Pedal Adjustment Pin Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
5. Longitudinal Pivot Bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
A. Longitudinal Pivot Bolt Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
B. Longitudinal Pivot Bolt Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 402
6. Pedal Shaft Assemblies - Left and Right Pilot Pedals . . . . . . . . . . . . . . . . . . . . . . . . . 402
A. Pedal Shaft Assemblies Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 402
B. Pedal Shaft Assemblies Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 402
C. Copilot Pedal Shaft Disengagement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 402
7. Crank Assembly, Right Pedal - Pilot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 403
A. Crank Assembly (Right Pedal) Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 403
B. Crank Assembly, (Right Pedal) Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 403
8. Crank Assembly, Left Pedal - Pilot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 403
A. Crank Assembly (Left Pedal) Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 403
B. Crank Assembly (Left Pedal) Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 403
9. Pedal Pivot Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 404
A. Pedal Pivot Support Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 404
B. Pedal Pivot Support Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 404
10. Pedal Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 404
A. Pedal Spring Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 404
B. Pedal Spring Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 404
11. Pedal Spring Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 404
A. Pedal Spring Support Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 404
B. Pedal Spring Support Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 404
12. Spring Return Arbor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 404
A. Spring Return Arbor Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 404
B. Spring Return Arbor Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 404
13. Pedal Return Springs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 405
A. Pedal Return Springs Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 405
B. Pedal Return Springs Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 405
14. FS 104.459 Lower Directional Crank Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 405
Page xi

A. Lower Directional Crank Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 405
B. Lower Directional Crank Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 405
15. Directional Pedal Link Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 405
A. Directional Pedal Link Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 405
B. Directional Pedal Link Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 405
16. Friction Disk . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 406
A. Friction Disk Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 406
B. Friction Disk Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 406
17. Friction Adjusting Retainer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 406
A. Friction Adjusting Retainer Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 406
B. Friction Adjusting Retainer Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 406
18. Friction Link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 406
A. Friction Link Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 406
B. Friction Link Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 406
19. Directional Interconnect Control Rod Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 406
A. Directional Interconnect Control Rod Assembly Removal . . . . . . . . . . . . . . . . . . . . 406
B. Directional Interconnect Control Rod Assembly Installation . . . . . . . . . . . . . . . . . 406
20. Directional Crank Assembly (FS 109.000) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 407
A. Directional Crank Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 407
B. Directional Crank Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 407
21. Pedal Directional Control Clevis Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 407
A. Pedal Directional Control Clevis Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . 407
B. Pedal Directional Control Clevis Assembly Installation . . . . . . . . . . . . . . . . . . . . . 407
22. Forward Cockpit Directional Control Rod Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 408
A. Forward Cockpit Directional Control Rod Assembly Removal . . . . . . . . . . . . . . . . 408
B. Forward Cockpit Directional Control Rod Assembly Installation . . . . . . . . . . . . . 408
23. Aft Cockpit Directional Control Rod Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 408
A. Aft Cockpit Directional Control Rod Assembly Removal . . . . . . . . . . . . . . . . . . . . . 408
B. Aft Cockpit Directional Control Rod Assembly Installation . . . . . . . . . . . . . . . . . . 408
24. Directional Lower Closet Bellcrank Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 409
A. Lower Closet Bellcrank Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 409
B. Directional Lower Closet Bellcrank Assembly Installation . . . . . . . . . . . . . . . . . . . 409
25. Directional Closet Control Rod Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 409
A. Directional Closet Control Rod Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . 409
B. Directional Closet Control Rod Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . 410
26. Directional Pedals Bracket Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 410
Page xii

A. Directional Pedals Bracket Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 410
B. Directional Pedals Bracket Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 410
27. Pedal Anticipator Assembly - Potentiometer (Transducer) (902 CONFIG) . . . . . . 411
A. Potentiometer Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 411
B. Potentiometer Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 411
28. Bracket, Potentiometer - Pedal Anticipator (902 CONFIG) . . . . . . . . . . . . . . . . . . . . 411
A. Potentiometer Bracket Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 411
B. Potentiometer Bracket Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 411
Figure 401.Anti-Torque/Directional Pedal Assembly (Sheet 1 of 2) . . . . . . . . . . 412
29. Directional Upper Closet Bellcrank Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 415
A. Directional Upper Closet Bellcrank Assembly Removal . . . . . . . . . . . . . . . . . . . . . 415
B. Directional Upper Closet Bellcrank Assembly Installation . . . . . . . . . . . . . . . . . . . 415
30. Directional Actuator Input Control Rod Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 415
A. Directional Actuator Input Control Rod Assembly Removal . . . . . . . . . . . . . . . . . 415
B. Directional Actuator Input Control Rod Assembly Installation . . . . . . . . . . . . . . . 415
31. Directional Actuator Output Control Rod Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 416
A. Directional Actuator Output Control Rod Assembly Removal . . . . . . . . . . . . . . . . 416
B. Directional Actuator Output Control Rod Assembly Installation . . . . . . . . . . . . . 416
32. Hydraulic Anti-Torque/Directional Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 416
A. Anti-Torque/Directional Actuator Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 416
B. Anti-Torque/Directional Actuator Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 416
33. Anti-Rotation Actuator Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 417
A. Anti-Rotation Actuator Bracket Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 417
B. Anti-Rotation Actuator Bracket Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 417
34. Actuator Attach Bracket Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 417
A. Actuator Attach Bracket Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 417
B. Actuator Attach Bracket Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 417
35. Splitter Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 418
A. Splitter Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 418
B. Splitter Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 418
36. Splitter Cam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 418
A. Splitter Cam Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 418
B. Splitter Cam Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 418
37. FS 231.500 Control Rod Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 419
A. FS 231.500 Control Rod Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 419
B. FS 231.500 Control Rod Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 419
Page xiii

38. Lateral Control Rod Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 419
A. Lateral Control Rod Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 419
B. Lateral Control Rod Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 419
39. Force Limiting Control Rod Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 420
A. Force Limiting Control Rod Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 420
B. Force Limiting Control Rod Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 420
40. FS 234.000 Directional Bellcrank Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 420
A. Directional Bellcrank Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 420
B. Directional Bellcrank Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 420
41. FS 234.000 Directional Bracket Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 421
A. Directional Bracket Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 421
B. Directional Bracket Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 421
42. FS 234.000 Directional Control Rod Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 421
A. Directional Control Rod Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 421
B. Directional Control Rod Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 421
43. FS 277.723 Directional Bellcrank Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 422
A. Directional Bellcrank Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 422
B. Directional Bellcrank Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 422
44. FS 277.723 Directional Bracket Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 422
A. Directional Bracket Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 422
B. Directional Bracket Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 422
45. Directional Fwd Cable Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 422
A. Directional Fwd Cable Bracket Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 422
B. Directional Fwd Cable Bracket Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 423
46. Fan Control Outer Bellcrank Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 423
A. Fan Control Outer Bellcrank Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . 423
B. Fan Control Outer Bellcrank Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . 423
47. Fan Control Lateral Control Rod Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 423
A. Fan Control Lateral Control Rod Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . 423
B. Fan Control Lateral Control Rod Assembly Installation . . . . . . . . . . . . . . . . . . . . . 423
48. Fan Control Inner Bellcrank Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 424
A. Fan Control Inner Bellcrank Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . 424
B. Fan Control Inner Bellcrank Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . 424
49. NOTAR Fan Control Shaft Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 424
A. Fan Control Shaft Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 424
B. Fan Control Shaft Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 424
Page xiv

Figure 402.Anti-Torque/Directional Control - Upper Deck (Sheet 1 of 2) . . . . . 425
50. Rotating Cone Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 428
A. Rotating Cone Cover Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 428
B. Rotating Cone Cover Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 428
51. Rotating Cone Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 428
A. Rotating Cone Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 428
B. Rotating Cone Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 428
52. Bearing Race, Rotating Cone Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 429
A. Bearing Race Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 429
B. Bearing Race Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 429
Figure 403.Rotating Cone Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 430
53. Sector Support Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 430
A. Sector Support Bracket Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 430
B. Sector Support Bracket Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 430
54. Sector Guard Clip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 431
A. Sector Guard Clip Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 431
B. Sector Guard Clip Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 431
55. Sector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 431
A. Sector Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 431
B. Sector Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 431
56. Sector Rigging Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 432
A. Sector Rigging Plate Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 432
B. Sector Rigging Plate Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 432
57. Sector Support Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 432
A. Sector Support Shaft Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 432
B. Sector Support Shaft Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 432
58. Sector Support Shaft Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 432
A. Sector Support Shaft Bracket Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 432
B. Sector Support Shaft Bracket Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 432
59. Rotating Cone Forward Control Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 433
A. Rotating Cone Forward Control Cable Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 433
B. Rotating Cone Forward Control Cable Installation. . . . . . . . . . . . . . . . . . . . . . . . . . 433
60. Rotating Cone Aft Control Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 433
A. Rotating Cone Aft Control Cable Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 433
B. Rotating Cone Aft Control Cable Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 433
61. Control Cable Pulley and Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 434
Page xv

A. Pulley Bracket Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 434
B. Pulley Bracket Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 434
C. Control Cable Pulley Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 434
D. Control Cable Pulley Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 434
62. Control Cable Drum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 434
A. Control Cable Drum Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 434
B. Control Cable Drum Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 434
63. Drum Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 435
A. Drum Bracket Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 435
B. Drum Bracket Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 435
64. Wire Braid Ground Jumper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 435
A. Wire Braid Ground Jumper Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 435
B. Wire Braid Ground Jumper Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 435
65. Rotating Cone Support Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 436
A. Rotating Cone Support Bearing Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 436
B. Rotating Cone Support Bearing Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 436
66. Lightning Strike Shield . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 436
A. Lightning Strike Shield Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 436
B. Lightning Strike Shield Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 436
67. Ground Jumper, Lightning Strike . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 437
A. Ground Jumper Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 437
B. Ground Jumper Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 437
Figure 404.Thruster and Controls Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 438
68. Rotating Cone Control Rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 439
A. Rotating Cone Control Rod Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 439
B. Rotating Cone Control Rod Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 439
69. Thruster . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 440
A. Thruster Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 440
B. Thruster Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 440
70. Forward Directional Control Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 440
A. Forward Directional Control Cable Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 440
B. Forward Directional Control Cable Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 441
C. Forward Directional Control Cable Forward Swivel Attach Bracket Removal . 442
D. Forward Directional Control Cable Forward Swivel Attach Bracket
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 442
E. Forward Directional Control Cable Forward Swivel Removal . . . . . . . . . . . . . . . . 443
F. Forward Directional Control Cable Forward Swivel Installation . . . . . . . . . . . . . 443
Page xvi

G. Forward Directional Control Cable Aft Swivel Attach Bracket Removal . . . . . . 443
H. Forward Directional Control Cable Aft Swivel Attach Bracket Installation . . . . 443
Figure 405.Thruster and Forward Directional Control Cable (Sheet 1 of 2) . . . 443
71. Vertical Stabilization Control System (VSCS) Control Unit . . . . . . . . . . . . . . . . . . . . 445
A. VSCS Control Unit Removal (Typical) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 445
B. VSCS Control Unit Installation (Typical) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 445
72. Yaw Rate Gyro . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 446
A. Yaw Rate Gyro Removal (Typical) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 446
B. Yaw Rate Gyro Installation (Typical) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 446
73. Right Lateral Accelerometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 446
A. Right Lateral Accelerometer Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 446
B. Right Lateral Accelerometer Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 446
74. VSCS Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 447
A. Actuator Removal (Typical) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 447
B. Actuator Installation (Typical) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 447
75. VSCS Control Rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 448
A. Control Rod Removal (Typical) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 448
B. Control Rod Installation (Typical) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 448
76. Tube Adapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 448
A. Tube Adapter Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 448
B. Tube Adapter Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 449
77. Spar Tube Bellcrank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 449
A. Bellcrank Removal (Typical) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 449
B. Bellcrank Installation (Typical) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 449
78. Horizontal Endplate Spar Tube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 450
A. Spar Tube Removal (Typical) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 450
B. Spar Tube Installation (Typical) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 450
Figure 406.Vertical Stabilization Control System . . . . . . . . . . . . . . . . . . . . . . . . . . 451
Inspection/Test/Rigging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601
1. Anti-Torque/Directional Controls System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601
A. Anti-Torque/Directional Controls System Inspection (Area 1) . . . . . . . . . . . . . . . 601
B. Anti-Torque/Directional Controls System Inspection (Area 2) . . . . . . . . . . . . . . . 601
C. Anti-Torque/Directional Controls System Inspection (Area 3) . . . . . . . . . . . . . . . 601
D. Anti-Torque/Directional Controls System Inspection (Area 6) . . . . . . . . . . . . . . . 602
E. Anti-Torque/Directional Controls System Inspection (Area 7) . . . . . . . . . . . . . . . 602
F. Anti-Torque/Directional Controls System Operational Test . . . . . . . . . . . . . . . . . . 603
Page xvii

G. Force Limiting Rod Break Out Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 603
Figure 601.Anti-Torque/Directional Controls (Sheet 1 of 2) . . . . . . . . . . . . . . . . . 604
H. Anti-Torque/Directional Control System Travel/Rigging Check . . . . . . . . . . . . . . 606
I. Anti-Torque/Directional Control System Rigging . . . . . . . . . . . . . . . . . . . . . . . . . . . 606
J. Pedal Anticipator (Transducer) Rigging (902 CONFIG) . . . . . . . . . . . . . . . . . . . . . 608
Figure 602.Anti-Torque/Directional Control System Rigging (Sheet 1 of 2) . . . 609
K. Pedal Forces Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 611
Figure 603.Pedal Forces Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 612
2. VSCS System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 612
A. VSCS System Inspection (Area 7) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 612
B. VSCS Spar Tube Inspection (Area 7) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 612
C. VSCS Rigging Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 613
Figure 604.VSCS System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 615
D. VSCS Operational Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 616
E. VSCS Fault Isolation Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 616
Figure 605.VSCS Diagnostics Test Box Right Installation (Typical) . . . . . . . . . . 618
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 801
1. Actuator, Anti-Torque/Directional - Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 801
2. Nicks, Scratches or Corrosion Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 801
3. Adapter (Fitting) Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 801
A. Lockring Retraction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 801
B. Adapter Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 802
C. O-ring Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 802
D. Adapter Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 802
E. Pressure Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 803
Figure 801.Anti-Torque/Directional Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 803
Figure 802.Lockring Retraction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 804
Figure 803.O-ring Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 804
Figure 804.Adapter/Lockring Removal and Installation . . . . . . . . . . . . . . . . . . . . 805
4. VSCS Actuator Regrease Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 805
A. VSCS Actuator Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 805
B. VSCS Actuator Regrease and Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 806
Figure 805.VSCS Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 808
Page xviii
MD Helicopters, Inc. CSP-900RMM-2
Section
670000
Flight Controls
FLIGHT CONTROLS
1. Flight Controls Cyclic Stick Base - Separates longitudinal
and lateral inputs and contains the secondary
The flight controls consist of the cyclic controls, cyclic control stops.
collective controls, upper flight controls,
anti-torque/directional controls, and vertical Longitudinal Trim Actuator - Allows the
stabilizer control subsystems. pilot to alleviate longitudinal cyclic stick flight
loads for trim flight conditions.
The MD900 helicopter is right command. The
helicopter may be equipped with either single Longitudinal Controls Balance Spring -
or dual pilot control installations. In a dual Balances longitudinal control load resulting
control helicopter the left main rotor controls from control component weight.
may be removed, the directional pedals
de-coupled and stowed, and covers placed over Longitudinal Linkages - Transmit longitu
the openings. dinal cyclic stick input to the upper flight
controls.
The main rotor flight controls combine pilot
inputs, from the cyclic and collective control Longitudinal Servoactuator - Hydraulical
stick assemblies, to control main rotor blade ly assists longitudinal linkage inputs to the
pitch. The cyclic and collective control stick upper flight controls.
inputs provide for longitudinal, lateral, and
vertical control. Lateral Trim Actuator - Allows the pilot to
alleviate lateral cyclic stick flight loads for
The anti-torque/directional pedal inputs are trim flight conditions.
transmitted to the anti-torque fan and direct
jet thruster for directional control, and Lateral Linkages - Transmit lateral cyclic
anti-torque. stick input to the upper flight controls.
Lateral Servoactuator - Hydraulically
2. Cyclic Controls Subsystem
assists lateral linkage inputs to the upper
(Ref. Figure 1) flight controls.
The cyclic controls subsystem provides A. Cyclic Stick Assembly
helicopter longitudinal and lateral control. The
cyclic controls move the upper controls to The cyclic stick assembly is located in front of
increase or decrease the main rotor blades the pilots seat. The cyclic stick is a curved
angle of attack in a cyclical manner around the aluminum tube with a control head and
main rotor azimuth. The result is a change in provides the pilot longitudinal and lateral
the helicopter pitch and/or roll attitude. The control of the helicopter. The cyclic stick is
cyclic control subsystem consists of the attached to the cyclic base. The cyclic base
following components: limits the range of travel at the cyclic grip to
11 inches longitudinally and 10 inches
Cyclic Stick Assembly - Provides pilot laterally.
control of helicopter pitch and/or roll attitude.
Cyclic stick inputs are transferred through
Cyclic Stick Centering Device - Assists the control linkages and push-pull tubes to the
pilot in centering the cyclic stick assembly, longitudinal and lateral hydraulic servoactua
both longitudinally and laterally, during tors. The servoactuators transmit cyclic inputs
engine start-up and shut-down. into the upper flight controls.
Page 1
CSP-900RMM-2 MD Helicopters, Inc.
A two way transmit switch, four way trim cyclic stick inputs. The pivoting bracket
switch, cargo hook release switch (if equipped), outputs the lateral cyclic stick inputs.
emergency float deploy switch (if equipped),
and auto pilot disconnect switch (if equipped) Incorporated into the pivoting bellcrank
are located on the cyclic stick assembly control bracket are secondary cyclic control stops.
grip. The transmit switch transmits on either Secondary cyclic control stops are machined as
the radio or intercommunications system. The part of the pivoting bracket and are not
trim switch controls the longitudinal and adjustable.
lateral trim actuators. Optional equipment E. Longitudinal and Lateral Trim Actuators
switches perform functions as indicated.
The longitudinal and lateral trim actuators
B. Copilot (Quick Release) Cyclic Stick are located below the pilot's seat under the
cockpit floor panel. The trim actuators
The quick release cyclic stick allows for the compensate for control loads from the main
removal and installation of the cyclic stick rotor system during flight. The actuators act
assembly without tools. The quick release through spring cartridges to provide gradient
cyclic stick is held in place by two spring clips force from the centered position the pilot
(expandable bolts). selects.
Single pilot operation using the quick release The cyclic trim switch, located on top of the
cyclic stick is prohibited. cyclic stick grip, has five positions: OFF at the
center, FORWARD, AFT, LEFT and RIGHT.
C. Cyclic Stick Centering Device When the trim button is moved from the
spring loaded OFF position to any of the four
The cyclic stick centering device, or centering trim directions, the trim actuators are
strap, is located on the front of the pilots cyclic energized, and the force gradient springs are
stick assembly. The strap is bolted to the cyclic repositioned to a new trim center.
stick at the top, and secured at the bottom, in
the stowed position, with a hook and loop Each trim actuator is an electrically energized
fastener. The strap is extended and aligned rotary actuator assembly installed in parallel
with the centering placard on the instrument to the longitudinal or lateral control path. The
panel directly in front of the cyclic stick. The actuators are secured to a bracket that is
centering device is used to aid the pilot in mounted to the forward fuselage substructure.
locating neutral cyclic stick position. Centering The cyclic trim gradient springs are linked to
the cyclic stick during engine start-up and the longitudinal and lateral linkages by dual
shut-down minimizes oscillatory loading of the attachment bellcranks.
main rotor flexbeams.
F. Longitudinal and Lateral Linkages
D. Cyclic Stick Base
The longitudinal and lateral linkages are
The cyclic stick base is attached to the located below the pilot's seat under the cockpit
underside of the cockpit floor directly aft of the floor, in the controls closet behind the pilot's
cyclic stick opening. The cyclic base splits the seat, in the cabin roof structure, and on the
longitudinal and lateral cyclic stick inputs into upper deck. The longitudinal and lateral
separate control paths. linkages move with cyclic input from the cyclic
stick assembly to control rods, located in the
The cyclic stick is attached to the longitudinal controls closet. The control rods in the controls
bellcrank which is mounted in the lateral closet move linkages in the cabin roof struc
bracket which pivots in the cyclic base. The ture to the longitudinal and lateral hydraulic
longitudinal bellcrank outputs longitudinal servoactuators.
Page 2
G. Longitudinal Controls Balance Spring H. Longitudinal and Lateral Hydraulic

Servoactuators
The longitudinal and lateral hydraulic
The longitudinal controls balance spring servoactuators are located on the upper deck
cancels (balances) longitudinal control load directly in front of the transmission. The
resulting from control component weight. The servoactuators use hydraulic power to assist
longitudinal balance spring is attached by a positioning of the upper flight controls.
bracket to the cockpit sub-structure. The
The longitudinal and lateral control primary
balance spring connects to the longitudinal control stops are internal to the servoactua
controls through an attach cable to an tors. Primary control stops are not adjustable
attachment clip. The attachment clip is for total control travel. Total control travel is
attached to the bottom connecting bolt of the moved by proportionately adjusting the
controls closet longitudinal control rod. servoactuator input and output.
Page 3
CYCLIC
CARGO HOOK TRIM
SWITCH REF.
RELEASE SWITCH UPPER DECK
AUTO PILOT CONTROLS
DISCONNECT
SWITCH
FLOAT
DEPLOY
SWITCH
LONGITUDINAL CLOSET
TRANSMIT CONTROL ROD
SWITCH LATERAL
VIEW ROTATED VIEW ROTATED CLOSET
CONTROL
SPRING CLIPS ROD
CYCLIC STICK
CENTERING STRAP LONGITUDINAL
BALANCE SPRING
ATTACH CLIP
LONGITUDINAL
CYCLIC STICK BRACKET
COPILOT LONGITUDINAL
QUICK DUAL CONTROLS BELLCRANK
RELEASE LONGITUDINAL
CYCLIC CONTROL CONTROL ROD LATERAL
STICK BOOT BRACKET
CYCLIC LONGITUDINAL
BASE CONTROL ROD
EXPANDABLE
DIAMETER BOLT
LONGITUDINAL LATERAL
CONTROL ROD BELLCRANK
LATERAL
CONTROL
STOP
LONGITUDINAL LATERAL
CONTROL STOP CONTROL ROD
LONGITUDINAL GRADIENT LATERAL GRADIENT

SPRING SPRING
LATERAL
LONGITUDINAL TRIM ACTUATOR BRACKET
LATERAL CONTROL TUBE
DUAL CONTROLS LATERAL LATERAL TRIM
ROD END BEARING LATERAL ACTUATOR CRANK
LONGITUDINAL BELLCRANK
LATERAL
TRIM ACTUATOR
TRIM ACTUATOR 9G67-002-1C
Figure 1. Cyclic Controls Subsystem (Sheet 1 of 2)
Page 4
UPPER CONTROLS
LONGITUDINAL MIXER ARM
LONGITUDINAL HYDRAULIC
SERVOACTUATOR
UPPER CONTROLS
LATERAL MIXER ARM
LONGITUDINAL
CONTROL ROD BOOT
LONGITUDINAL/COLLECTIVE
FOD COVER LATERAL HYDRAULIC
FOD COVER SERVOACTUATOR
LATERAL CONTROL ROD BOOT
LATERAL
FOD COVER
UPPER DECK
CONTROL BRACKET
UPPER DECK LONGITUDINAL ACTUATOR
LONGITUDINAL ACTUATOR ATTACH CLEVIS
CONTROL ROD
LONGITUDINAL
UPPER DECK CONTROL BELLCRANK
BRACKET LONGITUDINAL
BRACKET
LONGITUDINAL
CONTROL ROD
LATERAL ACTUATOR
ATTACH CLEVIS
LONGITUDINAL CONTROL SYSTEM

UPPER DECK LONGITUDINAL
BELLCRANK
LATERAL ACTUATOR
CONTROL ROD
LATERAL
LATERAL CONTROL ROD BELLCRANK
UPPER DECK
LATERAL BELLCRANK
UPPER DECK CONTROL

BRACKET
LATERAL
BRACKET
LATERAL
LATERAL CONTROL SYSTEM BRACKET
LATERAL
BELLCRANK
LATERAL CONTROL LINK
9G67-002-2B
Figure 1. Cyclic Controls Subsystem (Sheet 2 of 2)
Page 5
3. Collective Controls Subsystem A. Collective Stick Assembly

The collective stick assembly is located to the
left of the pilot's seat. The collective stick
(Ref. Figure 2) assembly is an aluminum tube that provides
the pilot with control of main rotor collective
pitch. The stick assembly has 10 inches of
Main rotor thrust is controlled by the collective vertical travel at the control module.
controls subsystem. As the collective stick
The collective stick assembly inputs are
assembly is raised or lowered, control linkages transferred through control linkages and
collectively increase or decrease the rotor push-pull tubes to the collective servoactuator.
blades pitch. The collective control subsystem The collective stick base incorporates the
consists of: adjustable collective stick down stop.
The engine manual throttle twist grips are
located on the collective stick assembly. The
Collective Stick Assembly - Provides pilot grips provide the pilot with manual engine
input into the collective control system. control in the event of an EEC failure. The
grips are positioned in the NORMAL detent
position for engine operation in the AUTO or
Collective Friction Unit - Assists in electronically controlled mode.
maintaining collective stick position, reducing Attached to the end of the collective stick
pilot workload. assembly is a control module. The control head
has electrical controls for: hover/landing lights,
collective friction release, N2 beep (if installed),
The friction unit provides collective position go around switch, take-off timer (if installed),
information to both engine EEC's and the EEC reset, yaw sync, and radio tuning.
IIDS. B. Copilot (Quick Release) Collective Stick
The quick release collective stick allows for the
Collective Friction Release Switch - removal and installation of the collective stick
Provides the pilot with control of the collective assembly without tools. The quick release
collective stick is held mechanically in place by
friction unit. a quick release pin. The stick has all the same
functions with the exception of the quick
release stick does not have a twist grip for
Collective Balance Spring - Balances engine throttle control.
collective control linkage weight loading.
Single pilot operation using the quick release
collective stick is prohibited.
Collective Sensor Transducer Assembly - C. Collective Friction Unit
Is a dual channel potentiometer which The collective friction unit is located below the
transmits collective stick position to the VSCS. collective stick assembly under the cockpit
floor panel.
Collective Linkages - Transmit collective The collective friction unit is an electrically

operated series of drum wrap springs that
stick input to the upper flight controls. provide friction to a set of drums. The first
series maintains friction at the 5 pound (2.27
kg) resistance level when the pilot releases
Collective Servoactuator - Hydraulically friction. The second series applies 25 pounds
assists collective linkage inputs to the upper (11.4 kg) of resistance when the pilot engages
flight controls. friction.
Page 6
The collective friction unit is linked to the F. Collective Controls Balance Spring
collective stick assembly by the collective
friction link.
The collective controls balance spring balances
D. Collective Friction Release Switch
collective control loads caused be control
The collective friction release switch is located component weight. The balance spring
on the under side of the collective stick control attaches to a bracket which is attached to
module. The collective friction release switch cockpit sub-structure, and to a clip attached to
allows the pilot to turn off friction by moving the bottom connecting bolt of the collective
the switch forward or momentarily release the closet control rod. An electrical tie down strap
friction by moving the switch aft. The momen
is installed loosely through the balance spring
tary release position is spring loaded to return
to the center or on position. The co-pilot's to retain the spring in position in the event of
collective control module has the momentary spring failure.
release function only.
E. Collective Linkages G. Collective Servoactuator
The collective linkages are located below the
pilots seat under the cockpit floor, in the
controls closet behind the pilot's seat, in the The collective servoactuator is located on the
cabin roof structure, and on the upper deck. upper deck in front of the transmission. The
The collective stick assembly inputs are hydraulic servoactuator assists control linkage
transmitted through the linkages and push- inputs to position main rotor upper flight
pull tubes to the collective servoactuator. controls.
Page 7
UPPER CONTROLS
COLLECTIVE MIXER
ARM
COLLECTIVE HYDRAULIC
SERVOACTUATOR
COLLECTIVE SERVOACTUATOR
CONTROL ROD
LONGITUDINAL/COLLECTIVE
FOD COVER
COLLECTIVE
BELLCRANK
COLLECTIVE
COLLECTIVE CLOSET BRACKET
CONTROL ROD COLLECTIVE
BELLCRANK
COLLECTIVE
DETENT MODULE CONTROL CONTROL ROD
BRACKET
POSITION
SENSOR LINK
DETENT MODULE
MOUNTING BRACKET
COLLECTIVE POSITION
ENGINE BALANCE SPRING SENSOR CRANK
MANUAL CONTROL ATTACH CLIP
TWIST GRIPS
POSITION TRANSDUCER
COLLECTIVE
POSITION SENSOR SENSOR BELLCRANK
PILOT BRACKET
COLLECTIVE STICK CLAMP BRACKET
COLLECTIVE FRICTION
RELEASE SWITCH COLLECTIVE POSITION
SENSOR INSTALLATION
COLLECTIVE ENGINE MANUAL CONTROL

STICK BOOT INTERCONNECT
CABLE
COPILOT
COLLECTIVE COLLECTIVE STICK
FRICTION UNIT
COLLECTIVE BELLCRANK COLLECTIVE

BRACKET BELLCRANK
COLLECTIVE STICK
MOUNTING BRACKET
COLLECTIVE INTERCONNECT
CONTROL ROD 9G67-011-1b
Figure 2. Collective Controls (Dual) Subsystem (Sheet 1 of 2)
Page 8
COLLECTIVE FRICTION
UNIT
COLLECTIVE FRICTION
ARM
COLLECTIVE FRICTION
COLLECTIVE LINK LINK
COLLECTIVE STICK
DOWN STOP
DUAL BEARING
ROD END
COLLECTIVE COLLECTIVE CLOSET

BELLCRANK CONTROL ROD
COLLECTIVE
CONTROL TUBE
COLLECTIVE BALANCE SPRING
COLLECTIVE ATTACH POINT
BRACKET
SEARCH LIGHT
LANDING/HOVER SWITCH (OPTION)
COLLECTIVE VIEW ROTATED 180
BELLCRANK LIGHT SWITCH SEARCH LIGHT
CONTROL SWITCH
LDG LIGHTS SRCH (OPTION)
EEC RESET YAW SYNC LT
TO AUTO YAW H O RET
N2 BEEP CURRENT V F
LANDING/HOVER R F
LIGHT SWITCH CONFIG L R GA
OFF IR
GO AROUND
SYNC EEC EXT SWITCH
LIGHTS SEARCH LIGHT SET
LDG CONTROL SWITCH T UP
EXT
HVR I
(OPTION) M L R AUTO PILOT
OFF L R GA
E YAW
GO AROUND TAKE-OFF R RESET
OFF DOWN (OPTION)
EEC RET SWITCH TIMER
HIGH
UP EARLY
R CONFIG
P R AUTO PILOT YAW COMMUNICATIONS
M YAW
RESET (OPTION) SWITCH
NORM DOWN
EEC RESET
COMMUNICATIONS TO AUTO
SWITCH
OFF YAW SYNC T/O
GATE
OFF GATE EARLY
RELEASE SWITCH CONFIG
EARLY CONFIG
902 CONFIG TIMER
YAW
TAKE-OFF TIMER
CURRENT CONFIG
YAW SYNC
CURRENT
900 C0NFIG CONFIG 9G67-011-2A
Figure 2. Collective Controls (Dual) Subsystem (Sheet 2 of 2)
Page 9
4. AntiTorque/Directional Controls necting linkage. There is no pedal adjustment

Subsystem stop on the copilots pedal cranks.
(Ref. Figure 3) 902 CONFIG
The NOTAR anti-torque controls subsystem A pedal anticipator is added to signal the EEC
provides the helicopter directional control. The of impending load demand increase caused by
anti-torque controls adjust NOTAR fan increased anti-torque fan pitch.
blade pitch and direct jet thruster position.
The anti-torque controls subsystem consists The pedal anticipator, on the pilots left pedal,
of: signals the electronic engine controls (EEC) of
an impending anti-torque fan pitch change.
Anti-Torque/Directional Pedals - Provide This allows the EEC's to anticipate any change
the pilot with directional control of the in power demand caused by fan pitch. The
helicopter around the vertical axis. pedal anticipator also provides the IIDS with
pedal position.
Anti-Torque/Directional Linkages -
Transmit pilot input to the NOTAR fan and A ground adjustable pedal friction device
the direct jet thruster. allows the amount of effort required to push
the pedals to be set. The friction is set to a
Anti-Torque/Directional Hydraulic predetermined value and is not to be used for a
Servoactuator - Transfers anti-torque pilot's friction preference.
linkage inputs to the splitter assembly.
The copilots pedals may be disengaged and
Splitter Assembly - Receives input from the moved far forward and secured. The pedals are
anti-torque/directional servoactuator, splits stowed by disengaging the adjustment pin and
NOTAR fan and direct jet thruster controls, positioning the pedal forward past the end of
and outputs varied differential control to the the pedal crank. A cover is then installed over
fan and thruster. the area to prevent objects or debris from
entering the controls.
The NOTAR Fan Linkages - Transfers
control input from the splitter to change B. AntiTorque/Directional Linkages
NOTAR fan blade pitch.
The anti-torque/directional linkages are
Direct Jet Thruster Linkages - Transfers located below the pilots seat under the cockpit
control input from the splitter assembly to the floor, in the controls closet located behind the
direct jet thruster. pilot's seat, and to the anti-torque/directional
servoactuator below the upper deck in the
A. AntiTorque/Directional Pedal Assembly cabin.
The anti-torque/directional pedal assembly is C. AntiTorque/Directional Servoactuator
attached to the forward side of fuselage station
106.0 bulkhead assembly in front of the pilot The anti-torque/directional servoactuator is
and copilots seats. The anti-torque/directional located under the upper deck on the right side.
pedals consist of two foot pedals with adjust The servoactuator transfers control linkage
ment pins to provide for forward and aft pedal inputs using hydraulic power to position the
adjustment, mounting brackets, and intercon splitter assembly.
Page 10
D. Splitter Assembly NOTAR fan pitch bearing. A bi-directional

force limiting control rod is installed between
The splitter assembly is located in the baggage the splitter and the diverter plate. In the event
compartment immediately aft of Fuselage of fan control input restriction, the force
Station 230.50. The splitter assembly receives limiting feature prevents damage to the fan
inputs from the directional servoactuator, control support structure while allowing
splits NOTAR fan and direct jet thruster continued control of the direct jet thruster.
controls, and outputs varied differential
control to the fan and thruster. F. Direct Jet Thruster Linkages
The splitter accomplishes varied differential The direct jet thruster linkages consist of a
control with a cam and follower arrangement. series of push-pull tubes, bellcranks, push pull
Differential control accommodates the cable, cable sector, tension cables, and cable
necessity for the fan pitch to be minimal when drum. The linkages transmit inputs from the
the thruster is closed, and at higher pitch splitter assembly to the direct jet thruster.
when the thruster is open either left or right.
The linkages are installed across the aft side of
The fan to thruster control relationship
fuselage station 230.5 frame assembly and aft
maintains constant air pressure inside the
to the tailboom. A pushpull cable is installed
tailboom, maintaining efficiency of the
through the tailboom to the thruster control
tailboom slots, and the anti-torque function of
rod assembly to the stationary thruster. The
the tailboom.
control rod connects to the thruster control
E. NOTAR Fan Linkages cable sector assembly on the upper side of the
stationary thruster.
The NOTAR fan linkages consist of a series
of push pull tubes and bellcranks that trans From the cable sector, control cables route to
mit inputs from the splitter assembly to the the thruster control cable drum mounted on
NOTAR fan pitch bearing. the aft side of the stationary thruster. The
direct jet thruster is attached to the thruster
The linkages run from the splitter assembly control cable drum with bolts. The direct jet
down the right side of the fuselage turning thruster turns about the thruster stationary
90 degrees left into the diverter plate assem cone assembly and the forward end rides on
bly and 90 degrees again forward to the the thruster control bearings.
Page 11
UPPER DECK
DIRECTIONAL
CLOSET DIRECTIONAL BELLCRANK
CONTROL ROD
PEDAL HEEL REST

ADJUSTMENT DIRECTIONAL
KNOB BELLCRANK
AFT DIRECTIONAL
CONTROL ROD
PEDAL
ADJUSTMENT DUAL CONTROL
STOP DIRECTIONAL PEDAL
PEDAL CRANK
CONTROL ROD
ATTACH BOLT
HEEL REST
PEDAL
CRANK
PEDAL
PILOT RIGHT FRICTION
DIRECTIONAL ASSEMBLY
PEDAL RIGHT
HEEL REST
902 CONFIG SUPPORT
PEDAL ANTICIPATOR LEFT
HOOK AND LOOP FASTENER
FOR STOWING PEDALS HEEL REST
DIRECTIONAL
SUPPORT
INTERCONNECT
CONTROL ROD
PEDAL DIRECTIONAL PEDAL

STOW LINK
BRACKET
COCKPIT AFT DIRECTIONAL
FLOOR CONTROL ROD
DIRECTIONAL
CRANK
PEDAL CRANK
PILOT RIGHT CONTROL ROD
PEDAL CRANK
9G67-012-1A
Figure 3. AntiTorque/Directional Controls Subsystem (Sheet 1 of 3)
Page 12
SPLITTER FAN INPUT FORCE

FOD ANTI-TORQUE/DIRECTIONAL ASSEMBLY LIMITING CONTROL ROD
COVER SERVOACTUATOR SPRING CAPSULE
ACTUATOR SUPPORT
UPPER BRACKET
DIRECTIONAL DECK DIRECTIONAL
BELLCRANK CONTROL ROD
DIRECTIONAL
CONTROL ROD
DIRECTIONAL DIRECTIONAL
DIRECTIONAL BELLCRANK
CONTROL ROD BRACKET
DIRECTIONAL
CONTROL ROD
UPPER DECK
DIRECTIONAL
CONTROL BRACKET
PUSH PULL
CABLE HOUSING
ATTACH BRACKET
DIRECTIONAL
BELLCRANK
DIRECTIONAL
BRACKET
TO THRUSTER
DIRECTIONAL
CONTROL CABLE
DIRECTIONAL
CONTROL ROD
OUTER BELLCRANK
DIVERTER PLATE FAN
CONTROL ROD
DIVERTER INNER BELLCRANK

PLATE
FAN CONTROL ROD
FAN INPUT FORCE

LIMITING CONTROL ROD
9G67-012-2A
Page 13
ROTATING CONE
ASSEMBLY
THRUSTER BUILDUP
ASSEMBLY
THRUSTER EXTENSION
ASSEMBLY
TAILBOOM
ASSEMBLY
THRUSTER
CONTROL ROD
THRUSTER
STATIONARY
CONE ASSEMBLY
DIRECTIONAL CONTROL
PUSH PULL CABLE
THRUSTER CONTROL ROD

THRUSTER CONTROL
CABLE SECTOR
FORWARD
THRUSTER CONTROL CABLE
AFT
THRUSTER CONTROL CABLE
THRUSTER
STATIONARY
CONE ASSEMBLY
LIGHTNING
STRIKE SHIELD
THRUSTER CONTROL
CABLE DRUM
CONTROL THRUSTER CABLE

BEARING DRUM BRACKET
VIEW ROTATED
9G67-012-3C
Page 14
5. Vertical Stabilization Control Subsystem C. VSCS Yaw Rate Gyros

(VSCS)
The yaw rate gyros are located in the left and
(Ref. Figure 4) right avionics bay, one on each side. The gyros
output a yaw rate signal to the VSCS control
The VSCS is a stability augmentation control units that is 80 mv/degree/second. They have a
system which uses the horizontal endplates to maximum rate output of 60 degrees/second.
augment directional control and stabilization. D. VSCS Control Units
The VSCS consists of the following compo
nents: The VSCS control units are located in the right
and left avionics bays. The control units are
Collective Control Position Transducer - independent from each other including power
provides collective stick assembly position to inputs, sensor inputs, and actuator interfaces.
the left and right VSCS control units. Each control unit internally monitors its power
supply and feedback sensors and provides a
Right Lateral Accelerometer - provides
failure annunciation on the IIDS of any
the helicopter lateral G force signal to the
detected faults.
right VSCS control unit.
The VSCS control units command the actua
VSCS Yaw Rate Gyros - provide a yaw rate tors over a range of "3 degrees from actuator
signal to the left and right VSCS control units. center based on collective position. The VSCS
control units use lateral accelerometer (right
VSCS Control Units - command left and only) and/or yaw rate gyro inputs to control
right VSCS linear actuator position. the actuators for the remainder of actuator
travel. The VSCS control units control the
VSCS Linear Actuators - controls move VSCS position indicators.
ment of the horizontal endplates.
E. VSCS Linear Actuators
Horizontal Endplates - augment and The linear actuators are located in the
stabilize helicopter movement around the horizontal stabilizer. Each linear actuator is
vertical axis. connected to a mounting bracket and to one of
the horizontal endplate spar tubes. The
VSCS Position Indicators - indicate
actuators control the position of the horizontal
horizontal endplate position.
endplates based on inputs from the VSCS
A. Collective Control Position Transducer control units.
The actuators have an internal servo loop that
The collective control position transducer is uses power and position commands supplied
located at the base of the collective controls by the VSCS control unit. The internal servo
closet control rod. The transducer is a dual loop returns actuator position to the control
channel DC rotary type position transducer units.
used to measure the collective stick assembly
position. Each channel uses "15 vdc for F. Endplate Spar Tube Assemblies
excitation and outputs a signal of the collective The endplate spar tube assemblies are
stick assembly position. The collective control installed into the journal bearings in the
position transducers provides position inputs horizontal stabilizer assembly. The spar tubes
to the left and right VSCS control unit. provide for the attachment of the cranks for
the VSCS actuators and installation of the
B. Right Linear Lateral Accelerometer horizontal endplates.
The linear lateral accelerometer is located in Each spar tube assembly consists of a spar
the right avionics bay. The accelerometer uses tube and spar tube sleeves. The tube is
"15 vdc input power and outputs a signal of machined from titanium alloy. The sleeves are
the the helicopter lateral G forces to the right machined from corrosion resistant steel and
VSCS control unit. The lateral acceleration mate with an interference fit onto the tubes in
signal is 3.75 vdc/g. the area of journal bearing contact.
Page 15
G. Upper and Lower Horizontal Endplates control the horizontal endplates through
control rods and cranks.
The horizontal endplates are mounted on the H. VSCS Position Indicators

endplate spar tube. The spar tube rotates in The VSCS position indicators indicate the
the horizontal stabilizer in upper and lower position of the horizontal endplates, and can
journal bearings. The VSCS linear actuators be used to evaluate the operation of the VSCS.
COLLECTIVE
POSITION
YAW RATE
TRANSDUCER
GYRO
LATERAL
ACCELEROMETER
RIGHT VSCS YAW RATE
CONTROL UNIT GYRO
UPPER RIGHT
HORIZONTAL RIGHT VSCS
ENDPLATE LINKAGE LEFT VSCS
CONTROL
UNIT
UPPER LEFT
HORIZONTAL
ENDPLATE
RIGHT LINEAR
ACTUATOR
VSCS POSITION
INDICATORS
LEFT
LINEAR
ACTUATOR
LEFT VSCS
LINKAGE
9G67-013B
Figure 4. VSCS Control Subsystem
Page 16
FLIGHT CONTROLS
FAULT ISOLATION
1. Rotor Flight Controls System Troubleshooting tables should be used with the
Troubleshooting simplified system schematics, electrical wiring
diagrams, serviceability checks and other
(Ref. Table 101) detailed procedures referred to in this and
other chapters of the manual.
brief summary of Rotor Flight Controls system in the Rotorcraft Maintenance Manual
faults, which may be encountered. CSP-900RMM-3 (Ref. Section 98-40-00).
Table 101. Main Rotor Flight Control System Troubleshooting

Excessive resistance Binding, restriction to or Verify hydraulic supply to 290000
against cyclic stick malfunction of lateral or actuator.
movements, longitudinally longitudinal servoactuator.
or laterally. Inspect actuator connections 671000
and operation, isolate damage,
remove and replace actuator if
necessary.
Upper deck swashplate/mix- Isolate damage or restriction 671000
er linkage restriction. and remove, repair, or replace.
Binding in controls linkage. Isolate damage or obstruction 671000
and remove, repair, or replace.
Cyclic control pressure Faulty wiring. Test and repair wiring. 980000
cannot be reduced by
operating trim switch. Faulty connection. Troubleshoot trim actuator 671000
connection.
Trim switch inoperative. Troubleshoot actuator trim 671020
switch on cyclic grip.
Trim resistor failed. Test and/or replace trim 671000
resistor.
Trim actuator inoperative. Replace actuator. 671000
Trim change is too slow. Trim resistor failed. Test and/or replace trim 671000
resistor.
Defective trim actuator. Replace actuator. 671000
Trim change is too fast. Trim resistor failed. Test and/or replace trim 671000
resistor.
Binding, locking up or Control rod restrictions or Inspect control rod 671000
erratic action of cyclic misalignment. connections, rod end condition
control stick. and bearing movement, replace
or repair as required.
Control linkage restriction or Isolate restriction or damage 671000
damage. and remove, repair, or replace.
Page 101
67-00-00 Revision 4
Table 101. Main Rotor Flight Control System Troubleshooting (Cont.)

Inadequate cyclic control Aircraft is loaded out of Verify and correct weight and 080000
movement or response center of gravity range. balance.
during flight.
Incorrect cyclic rigging. Correct cyclic rigging. 671000
Excessive resistance Restriction caused by Release CFU from previous 671000

against collective stick collective friction unit (CFU). locked position.
movement, upward or
downward. Binding, restriction or Verify hydraulic supply to 290000
malfunction to collective actuator.
servoactuator.
Inspect actuator connections 671000
and operation, isolate damage,
remove and replace actuator if
necessary.
Upper deck swashplate/mix- Isolate damage or restriction 671000
er linkage restriction. and remove.
and remove.
Collective stick pressure Faulty connection. Troubleshoot CFU connection. 671000

does not release when
collective friction unit (CFU) Faulty wiring. Test and repair wiring. 980000
release button is depressed. Release switch inoperative. Troubleshoot switch on 671020
collective control module
(collective grip) to CFU
connection and operation.
Collective Friction Unit Replace CFU. 671000
inoperative.
Binding, locking up or Control rod restrictions or Inspect control rod 671000

erratic action of collective misalignment. connections, rod end condition
control stick motion. and bearing movement, replace
as required.
Control linkage restriction or Isolate restriction or damage 671000
damage. and remove.
Possible damage to uniball Remove and replace 623000
bearing or static mast. swashplate.
Inadequate collective Aircraft may be above or Verify weight, reduce load if CSP900RFM1
control movement or near maximum take off required. or
response during normal weight. CSP900RFM1
operation.
Incorrect collective rigging. Correct collective rigging. 671000
NCFAL1=1 on IIDS Faulty wiring. Test and repair wiring. 980000

alphanumeric display
CLP resolver drift (CFU). Replace Collective Friction 671000
Unit.
Page 102
Revision 4 67-00-00
Table 101. Main Rotor Flight Control System Troubleshooting (Cont.)

NCFAL1=3 on IIDS Faulty wiring. Test and repair wiring. 980000
CLP gain failure (CFU) Replace Collective Friction Unit 671000
NCFAL1=5 on IIDS Faulty wiring Test and repair wiring 980000
CLP sine failure (CFU) Replace Collective Friction Unit 671000
CLP cosine failure (CFU) Replace Collective Friction Unit 671000
CLP calculation failure Replace Collective Friction Unit 671000
(CFU)
Page 103
67-00-00 Revision 4
2. AntiTorque/Directional Flight Controls Troubleshooting tables should be used with the

Troubleshooting simplified system schematics, electrical wiring
diagrams, serviceability checks and other
(Ref. Table 102) detailed procedures referred to in this and
brief summary of Anti-Torque/Directional Comprehensive wiring diagrams are available
Flight Controls System faults, which may be in the Rotorcraft Maintenance Manual
encountered. CSP-900RMM-3 (Ref. Section 98-40-00).
Table 102. AntiTorque/Directional Flight Control System Troubleshooting
Excessive resistance against Restriction against rotating Isolate restriction or damage 672000
antitorque/directional pedal jet thruster. and remove, repair, or replace.
movements.
Binding, restriction, or Verify hydraulic supply to 290000
malfunction of directional actuator.
servoactuator.
Inspect actuator connections 672000
and operation, isolate damage
Replace actuator. 672000
Thruster control bearings Inspect and replace bearings 672000
worn. as required.
Binding, locking up or erratic Control rod restrictions or Inspect control rod 672000
action of pedal movement. misalignment. connections, rod end condition
and bearing movement, replace
components as required.
worn. as required.
Pedal anticipator not sending Faulty Wiring. Test and repair wiring. 980000
message to EECs.
Mechanical linkage. Inspect potentiometer 672000
installation.
Potentiometer malfunction. Inspect potentiometer, wiring 672000
connection. 984000
Replace Potentiometer. 672000
Page 104
Table 102. AntiTorque/Directional Flight Control System Troubleshooting (Cont.)

Degraded movement or Restriction or malfunction at Inspect splitter range and 672000
response of notar fan control splitter assembly. freedom of movement. Repair
linkage. or replace as required.
Degraded travel of force Isolate damage or malfunction
limiting control rod or difuser and repair or replace
bellcrank connections. components.
Incorrect antitorque/direc- Correct rigging. 672000
tional rigging.
worn. as required.
Inadequate or irregular Friction or binding at Inspect and clean bearings. 672000

antitorque/directional endplate spar tube bearings.
movement or response
during flight. Incorrect antitorque/direc- Correct rigging. 672000
tional rigging.
worn. as required.
Degraded operation of Faulty wiring. Test and repair wiring. 980000

vertical stabilizer endplates
when collective stick is Collective position Adjust collective position 672000
moved through its range of transducers improperly transducers.
travel. adjusted.
Incorrect VSCS rigging. Correct rigging. 672000
Malfunction of VSCS Perform VSCS Test Box and 672000
component. System Diagnostics
Procedures Replace
malfunctioned component.
Restriction between actuator Remove restriction, repair, or 672000
and endplate linkage. replace damaged component.
Noticeable dutch roll of Faulty wiring. Test and repair wiring. 980000
aircraft.
Malfunction of right yaw rate Perform VSCS Test Box and 672000
gyro. System Diagnostics
Procedures. Replace yaw rate
gyro.
Malfunction of left yaw rate Perform VSCS Test Box and 672000
gyro. System Diagnostics
Procedures. Replace yaw rate
gyro.
Vertical stabilizer endplates Faulty wiring. Test and repair wiring. 980000
will not hardover in a hover or
difficulty making a Malfunction of lateral Perform VSCS Test Box and 672000
coordinated turn. accelerometer. System Diagnostics
Procedures. Replace lateral
accelerometer.
Page 105

Slight or no response of Faulty wiring. Test and repair wiring. 980000
vertical stabilizer endplates
observed on the left or right Faulty collective position Perform VSCS Test Box and 672000
actuator position indicator transducers. System Diagnostics
when collective stick is Procedures. Replace collective
moved on takeoff. position transducers.
No movement of vertical Faulty wiring. Test and repair wiring. 980000

stabilizer endplates when
collective stick is moved Faulty VSCS component. Perform VSCS Test Box and 672000
through its entire range of System Diagnostics
motion. Procedures Replace faulty
component.
Faulty connection or Remove restriction, repair, or 672000
restriction between actuator Replace damaged component.
and endplate.
LEFT STAB FAIL, RIGHT Faulty wiring. Test and repair wiring. 980000
STAB FAIL or TOTAL STAB
FAIL message present on Faulty VSCS component. Perform VSCS Test Box and 672000
alpha numeric display of System Diagnostics
IIDS. Procedures. Replace faulty
component.
No deflection in lightning Liquid shim in this area too Sand liquid shim minimum 672000
strike contact; no measurable thick. required while maintaining an
gap between contact and even surface for mating part
cone surface. (See Notes).
Measurable gap between Lightning strike contact Replace lightning strike 672000
contact and cone surface, no warped or bent. contact.
contact with guide pin.
Deflection verified, Pin surface and/or contact Reprepare surfaces for 900CSPSPM
measurable gap exists, surface contaminated or electrical bonding.
contact fails bond check. corroded.
Guide pin not properly Test and repair. 900CSPSPM
grounded. 672000
NCFUR 1=2 on IIDS Faulty wiring. Test and repair wiring. 980000
alphanumeric display.
Pedal Potentiometer. Replace potentiometer. 672000
EEC. Ref. P&WC Fault Isolation 010000
Charts (Ref. Related
Page 106

NOTES:
(1) Maximum thickness of shim material (C409) not to exceed .015 in. above surface of cone. Area to be
2.753.25X2.753.25 in. square. Use sandpaper (C807) (Dry Method) and epoxy paste adhesive (C409)
(Ref. 900CSPSPM).
Page 107
Page 108
Section
671000
Rotor Flight
Controls
ROTOR FLIGHT CONTROLS

1. Collective Stick Boot 3. Pilot Collective Control Stick Assembly
A. Collective Stick Boot Removal

(1). Pull collective stick boot (1) hook and (Ref. CSPSPM)
loop fastener from floor. Item Nomenclature
(2). Remove boot (1) from around collective C220 Compound, AntiSeize
control stick (2).
C702 Lockwire
B. Collective Stick Boot Installation
Special Tools
(1). Install collective stick boot on collective (Ref. CSPSPM)
control stick. Item Nomenclature
T2002 Ground Power Unit
(2). Push hook and loop fasteners together
against floor and around collective
stick. A. Pilot Collective Control Stick Assembly
Removal
2. Collective Control Module
(1). Remove pilot crew seat (Ref. Section
(Ref. Figure 401) 25-10-00).
A. Collective Control Module Removal (2). Remove collective stick boot.
(1). Disconnect electrical connector P1 (3). (3). Remove access panel AR138, AR145,
and B142 (Ref. Section 06-00-00).
Do not remove or loosen the hex
CAUTION head screws in the throttle twist (4). Disconnect electrical connector P2 (25).
grips. This could cause a disengagement of Be careful when you disconnect
the manual throttle mechanism. CAUTION mechanical engine control ca
bles. If you are not careful, damage to con
(2). Align holes in mechanical engine
trol cables can occur.
controls twist grip (23) as necessary
and remove screw (24). NOTE: Mark left and right mechanical engine
control cables (5).
(3). Remove control module (4).
(5). Remove and discard lockwire. Discon
B. Collective Control Module Installation nect mechanical engine control cables
(5).
(1). Install control module on end of
collective stick. NOTE: DUAL CONTROLS - Mark the left
and right mechanical engine control inter
(2). Align holes in mechanical engine connect cables (27).
controls twist grip as necessary and
install screw. Torque screw. (6). DUAL CONTROLS - Remove and
discard lockwire, disconnect mechanical
(3). Connect electrical connector P1. engine control interconnect cables (27).
(4). Do the mechanical engine controls (7). Apply external electrical power, use
operational check (Ref. Section ground power unit (T2002) (Ref.
76-00-00). CSP-900RMM-3).
Page 401
Moving Flight Controls Sealant, Fuel Resistant (C216)
(8). Pull collective friction release switch (4). Environmentally seal bonding jumper
and lift pilot collective stick (2) to with sealant (C216) (Ref. CSP-SPM).
approximately 15 to 30 percent shown
on IIDS to unload collective controls. (5). Connect collective link and install bolt,
washers, and nut. Torque nut and
(9). Remove external electrical power (Ref. install new cotter pin.
CSP-900RMM-3).
(6). Connect collective friction unit link and
(10). Remove cotter pin (6) from bolt (9). install bolt, washers, and nut. Torque
nut and install new cotter pin.
(11). Remove nut (7), washers (8, 11 and 29),
and bolt (9) and disconnect collective Compound, Anti-Seize (C220)
link (12).
(12). Remove cotter pin (6) from bolt (9).
support collective stick when

CAUTION you remove bolt (9).
(7). Apply anti-seize compound (C220) to
threads of mechanical engine control
collective stick fittings.
(13). Remove nut (7), washers (8), and bolt
(9) and disconnect collective friction Be careful when you connect
unit link (10). CAUTION mechanical engine control ca
bles. If you are not careful damage to control
(14). Remove environmental seal from cables can occur.
bonding jumper at outer collective stick
attach nut (7). (8). Connect mechanical engine control
cables. Torque cable end nuts 60-80 in
(15). Remove cotter pin (6) from bolts (13). lb (6.78-9.04 Nm) and safety with
lockwire (C702).
(16). Remove nuts (7), washers (8 and 11),
bonding jumper (right side only), and (9). DUAL CONTROLS - Connect me
bolts (13). Remove collective stick (2). chanical engine control interconnect
cables. Torque cable end nuts 60-80 in
B. Pilot Collective Control Stick Assembly lb (6.78-9.04 Nm) and safety with
Installation lockwire (C702).
(1). Prepare inner surface of outer collective (10). Connect electrical connector P2.
stick bracket to collective stick attach
point for electrical bond (Ref. CSP- (11). Do the mechanical engine controls
SPM). operational check (Ref. Section
76-00-00).
(2). Put collective stick in collective stick
bracket and install bolts, washers, (12). Install access panel AR138, AR145, and
bonding jumper (right side only), and B142 (Ref. Section 06-00-00).
nuts. Torque nuts and install new
cotter pins. (13). Install collective stick boot.
(3). Do a test on collective stick for Class (14). Install pilot crew seat (Ref. Section
L electrical bond (Ref. CSP-SPM). 25-10-00).
Page 402
4. Collective Friction Unit Link Assembly (4). Install collective stick boot.
(Ref. Figure 401) (5). Do steps (9). through (12). of collective
controls system rigging (lower).
Special Tools 5. Collective Friction Unit Arm Assembly
(Ref. CSPSPM)
Special Tools
(Ref. CSPSPM)
A. Collective Friction Unit Link Assembly Item Nomenclature
Removal
(1). Remove collective stick boot (1).
(2). Remove access panel B142 (Ref. Section A. Collective Friction Unit Arm Assembly
06-00-00). Removal
(3). Apply external electrical power, use (1). Remove center access panel B142 (Ref.
ground power unit (T2002) (Ref. Section 06-00-00).
CSP-900RMM-3). (2). Apply external electrical power, use
Moving Flight Controls ground power unit (T2002) (Ref.
CSP-900RMM-3).
Moving Flight Controls
(4). Pull collective friction release switch

and lift pilot collective stick (2) to
approximately 15 to 30 percent shown (3). Pull collective friction release switch
on IIDS to unload collective controls. and lift pilot collective stick (2) to
(5). Remove external electrical power (Ref.
on IIDS to unload collective controls.
CSP-900RMM-3).
(6). Remove cotter pin (6) from (9).
CSP-900RMM-3).
(7). Remove nut (7), washers (8), and bolt (5). Remove cotter pin (6) from bolt (9).
(9).
(8). Remove cotter pin (6) from (9). (9).
(9). Remove nut (7), washers (8), and bolt (7). Remove nut (18), washer (17), and bolt
(9). Remove collective friction unit link (16).
(10).
(8). Move arm (15) away from friction unit
B. Collective Friction Unit Link Assembly (19) to remove.
Installation
B. Collective Friction Unit Arm Assembly
(1). Install collective friction unit link ,bolt, Installation
washers, and nut. Torque nut and
install new cotter pin. NOTE: Collective friction unit shaft has a mis
sing spline for arm alignment.
(2). Install bolt, washers, and nut. Torque
nut and install new cotter pin. (1). Put collective friction unit arm on
collective friction unit splines and
(3). Install access panel B142 (Ref. Section install bolt, washers, and nut. Torque
06-00-00). nut.
Page 403
(2). Install bolt, washers, and nut. Torque (5). Disconnect electrical connector P153
nut and install new cotter pin. (20).
(3). Install center access panel B142 (Ref. (6). Remove cotter pin (6) from bolt (9).
Section 06-00-00).
(4). Do steps (9). through (12). of Collective (9).
Controls System Rigging (Lower). (8). Remove environmental seal from
around collective friction unit (19).
6. Collective Friction Unit
(Ref. Figure 401) collective friction unit (19).
B. Collective Friction Unit Installation
(Ref. CSPSPM) (1). Prepare collective friction unit to
Item Nomenclature structure mating surfaces for electrical
C216 Sealant, Fuel Resistant bond (Ref. CSP-SPM).
(2). Put collective friction unit in its
Special Tools installed position and installbolts and
(Ref. CSPSPM) washers. Torque bolts.
Item Nomenclature
(3). Do a test on collective friction unit for
T2002 Ground Power Unit Class L electrical bond (Ref. CSP-
SPM).
A. Collective Friction Unit Removal Sealant, Fuel Resistant (C216)
(1). Remove center access panel B142 (Ref.
Section 06-00-00).
(2). Apply external electrical power, use
ground power unit (T2002) (Ref. (4). Environmentally seal collective friction
CSP-900RMM-3). unit, use sealant (C216) (Ref. CSP-
SPM).
Flight Control Movement
CAUTION (5). Install bolt, washers, and nut. Torque
approximately 15 to 30 percent shown (7). Install center access panel B142 (Ref.
on IIDS to unload collective controls. Section 06-00-00).
(4). Remove external electrical power (Ref. (8). Do steps (9). through (12). of Collective
CSP-900RMM-3). Controls System Rigging (Lower).
Page 404
4
23
2
1
28 24
9 20
19
21
8 4 PL
22
26
25
27 TO COPILOT'S
COLLECTIVE
16 (DUAL CONTROLS)
7 11
8 8 17
6 9
7 6 15
18
10 8
29
7
29 TO MANUAL ENGINE CONTROLS
6 DETENT MODULE
13
11 8
9 5 (NOTE)
7
6
8 8
6
12 7
11
14 13
MECHANICAL ENGINE CONTROL

CABLE COUPLING (TYPICAL) 9G67-053B
1. COLLECTIVE STICK BOOT 16. BOLT
2. COLLECTIVE CONTROL STICK ASSEMBLY 17. WASHER
3. ELECTRICAL CONNECTOR P1 18. NUT
4. COLLECTIVE CONTROL MODULE 19. COLLECTIVE FRICTION UNIT
5. MECHANICAL ENGINE CONTROL CABLE 20. ELECTRICAL CONNECTOR P153
ASSEMBLIES 21. BOLT
6. COTTER PIN
22. WASHER
7. NUT
23. MECHANICAL ENGINE CONTROLS TWIST GRIP
8. WASHER
24. SCREW
9. BOLT
10. COLLECTIVE FRICTION UNIT LINK ASSEMBLY 25. ELECTRICAL CONNECTOR P2
11. WASHER 26. ELECTRICAL RECEPTACLE J120
12. COLLECTIVE LINK ASSEMBLY 27. MECHANICAL ENGINE CONTROLS INTERCONNECT
13. BOLT CABLE ASSEMBLIES
14. COLLECTIVE STICK BRACKET ASSEMBLY 28. COLLECTIVE STICK WIRE HARNESS
15. COLLECTIVE FRICTION UNIT ARM 29. WASHER
Figure 401. Collective Stick and Collective Friction Installation
Page 405
7. Collective Stick Link Assembly (3). Install access panel AR145 and B142
(Ref. Figure 402)
(4). Install collective stick boot.
Special Tools (5). Install pilot crew seat (Ref. Section
(Ref. CSPSPM) 25-10-00).
Item Nomenclature
8. Collective Cockpit Control Tube
Assembly
(Ref. Figure 402)
A. Collective Stick Link Assembly Removal
A. Collective Cockpit Control Tube
(1). Remove pilot crew seat (Ref. Section Assembly Removal
25-10-00).
(2). Remove collective stick boot (1). 25-10-00).
(3). Remove access panel AR145 and B142 (2). Remove floor access panel AR138 and
(Ref. Section 06-00-00). B142 (Ref. Section 06-00-00).
(4). Apply external electrical power, use (3). DUAL CONTROLS - Remove cotter
ground power unit (T2002) (Ref. pin (6) from bolt (50).
CSP-900RMM-3). (4). DUAL CONTROLS - Remove nut (7),
washers (11), and bolt (50) disconnect
interconnect control rod (21).
(6). Remove nut (7), washers (8), bushing
(22), and bolt (45).
and lift pilot collective stick (2) to (7). Remove cotter pin (6) from bolt (13).
on IIDS to unload collective controls. (8). Remove nut (7), washers (11), and bolt
(13). Remove control tube (17).
B. Collective Cockpit Control Tube
CSP-900RMM-3).
(7). Remove cotter pin (6) from bolt (9). (1). If a replacement control tube is
installed, make sure new control tube is
(8). Remove nut (7), washers (11, 51, and
set to the same length as removed
8), and bolt (9).
control tube.
(9). Remove cotter pin (6) from bolt (18). (2). Install control tube, bolt (45), bushing,
washers, and nut. Torque bolt and
install new cotter pin.
(18). Remove collective link (12).
(3). Install bolt (13), washers, and nut.
B. Collective Stick Link Assembly Torque bolt and install new cotter pin.
Installation
(4). DUAL CONTROLS - Connect inter
(1). Install collective link, bolt (18), washers connect control rod and install bolt (50),
and nut. Torque nut and install new washers, and nut. Torque bolt and
cotter pin. install new cotter pin.
(2). Install bolt (9), washers, and nut. (5). Do the collective control system part of
Torque nut and install new cotter pin. the rotor flight controls rigging check.
Page 406
(6). Install floor access panel AR138 and (5). Remove nuts (27), washers (8), and
B142 (Ref. Section 06-00-00). bolts (28). Remove collective stick
bracket (14).
(7). Install pilot crew seat (Ref. Section
25-10-00). B. Collective Stick Bracket Assembly
Installation
9. Collective Stick Bellcrank Assembly (1). Prepare mating surfaces of collective
(Ref. Figure 402) stick bracket and structure for electri
cal bond (Ref. CSP-SPM).
Consumable Materials (2). Install collective stick bracket, bolts,

(Ref. CSPSPM) washers, and nuts. Torque nuts.
Item Nomenclature (3). Do a test on collective stick bracket for
C216 Sealant, Fuel Resistant Class L electrical bond (Ref. CSP-
SPM).
A. Collective Stick Bellcrank Assembly Sealant, Fuel Resistant (C216)

Removal
(1). Remove collective link assembly.
(2). Disconnect inner end of collective (4). Environmentally seal collective stick
cockpit control tube. bracket, use sealant (C216) (Ref.
CSP-SPM).
(5). Put collective stick bellcrank in its
(4). Remove nut (7), washers (8 and 11) and installed position and install bolt,
bolt (19). Remove bellcrank (16). washers, and nut. Torque bolt and
B. Collective Stick Bellcrank Assembly
Installation (6). Install pilot collective stick.
(1). Install bellcrank, bolt, washers, and 11. Collective Closet Control Tube Assembly
pin. (Ref. Figure 402)
A. Collective Closet Control Tube Assembly
(2). Connect inner end of collective cockpit
Removal
control tube.
(3). Install collective link assembly. 25-10-00).
10. Collective Stick Bracket Assembly (2). Remove floor access panel AR138 (Ref.
Section 06-00-00).
(Ref. Figure 402)
(3). Remove insulation and controls closet
A. Collective Stick Bracket Assembly panels behind right crew seat (Ref.
Removal Section 25-10-00).
(1). Remove pilot collective stick. (4). Remove cotter pin (6) from bolt (46).
(5). Remove nut (7), washers (8), bolt (46),
(2). Remove (6) from bolt (19). spacer (15), grommet (10), and spring
(3). Remove nut (7), washers (8 and 11) and attach clip (5).
bolt (19). (6). Remove cotter pin (6) from bolt (4).
(4). Remove fillet seal from around collec (7). Remove nut (7), washers (8), and bolt
tive stick bracket (14). (4). Remove closet control tube (43).
Page 407
B. Collective Closet Control Tube Assembly Moving Flight Controls

Installation
(1). If a replacement control tube is

installed, make sure new control tube is
set to the same length as removed (4). Pull collective friction release switch
control tube. and lift pilot collective stick (2) to
(2). Install collective closet control tube, on IIDS to unload collective controls.
bolt (4), washers, and nut. Torque nut (5). Remove external electrical power (Ref.
and install new cotter pin. CSP-900RMM-3).
(3). Install bolt (46), washers, spring clip, NOTE: Make a mark adjacent to the hole bal
grommet, spacer, and nut. Torque nut ance spring is installed in on lower collective
and install new cotter pin. balance spring bracket (39).
(4). Do the collective control system part of (7). Remove nut (7), washers (8), bolt (46),
the rotor flight controls rigging check. spacer (15), grommet (10) and spring
attach clip (5).
(5). Install controls closet and insulation
panels behind right crew seat (Ref. (8). Remove balance spring (36) from lower
Section 25-10-00). collective balance spring bracket (39).
(9). Remove spring attach clip (5) from
(6). Install floor access panel AR138 (Ref. balance spring (36).
Section 06-00-00). B. Collective Controls Balance Spring
Installation
25-10-00). (1). Install balance spring in hole in lower
attach bracket with mark.
12. Collective Controls Balance Spring (2). Install spring attach clip on upper end
of balance spring.
(Ref. Figure 402) (3). Install bolt, spring attach clip, washers,
grommet, spacer, and nut. Torque nut
and install new cotter pin.
Special Tools
(Ref. CSPSPM) (4). Apply external electrical power, use
Item Nomenclature ground power unit (T2002) (Ref.
CSP-900RMM-3).
T2001 Hydraulic Mule
A. Collective Controls Balance Spring

Removal (5). Apply 1000 psig (6894.8 kPa) hydrau
lic pressure to hydraulic system
(1). Remove pilot crew seat (Ref. Section number 1, use hydraulic mule (T2001)
25-10-00). (Ref. Section 29-00-00).
Balance spring tie down strap
(2). Remove floor access panel AR138 (Ref. CAUTION must not have an interference
Section 06-00-00).
with balance spring when collective stick is
(3). Apply external electrical power, use in the full down position.
ground power unit (T2002) (Ref. (6). Pull pilot collective friction release
CSP-900RMM-3). switch and move collective stick to the
Page 408
full down position. Make sure tie down (7). Remove nut (7), four washers (8),
strap is loose on balance spring. If tie bushing (22) and bolt (45).
down strap is not loose, replace strap.
(8). Remove wires from module block (34)
(7). Remove hydraulic pressure (Ref. (Ref. CSP-SPM).
Section 29-00-00).
(8). Remove external electrical power (Ref. collective position sensor assembly (35).
CSP-900RMM-3).
B. Collective Position Sensor Assembly
(9). Install floor access panel AR138 (Ref. Disassemble
Section 06-00-00).
25-10-10). (2). Remove nut (7), washers (20), and bolt
(24). Remove sensor link (25).
13. Collective Position Sensor Assembly (3). Remove cotter pin (6) from bolt (41).
(Ref. Figure 402) (4). Remove nut (7), washers (8), and bolt
(41). Remove sensor bellcrank (44).
Special Tools
(Ref. CSPSPM) (5). Remove screws (23), washers (8), and
Item Nomenclature potentiometer clamps (49). Remove
sensor transducer (47)
T2002 Ground Power Unit C. Collective Position Sensor Assembly
T1001 Analog Multimeter, Portable Reassemble
(1). If sensor transducer is new, do the
A. Collective Position Sensor Assembly procedure that follows:
Removal
(a). Do a test for resistance on each half
(1). Remove pilot crew seat (Ref. Section of the sensor transducer, use analog
25-10-00). multimeter (T1001)
(2). Remove floor access panel AR138 (Ref. (b). If the resistance is not the same,
Section 06-00-00). loosen screw on clamp between each
half and set both parts of transducer
(3). Apply external electrical power, use to the same resistance. Tighten screw
ground power unit (T2002) (Ref. on clamp sufficiently to prevent
CSP-900RMM-3). movement between the two parts.
Moving Flight Controls (2). Install sensor transducer, screws,

washers, and potentiometer clamps.
Torque screws.
Do not damage sensor bellcrank
CAUTION when you install bolt (41) or
(4). Pull collective friction release switch torque nut (7).
approximately 15 to 30 percent shown (3). Install sensor bellcrank, bolt, washers,
on IIDS to unload collective controls. and nut. Torque nut and install new
cotter pin.
CSP-900RMM-3). (4). Install sensor link, bolt, washers, and
(6). Remove cotter pin (6) from bolt (45). pin.
Page 409
D. Collective Position Sensor Assembly (a). If indication is incorrect, loosen screw

Installation on clamp on transducer and turn
forward half of transducer to get the
(1). Install collective sensor assembly, bolts, correct indication. Tighten screw on
and washers. Torque bolts. clamp sufficiently to prevent move
ment of forward half of transducer.
(2). Connect collective cockpit control tube
and install bolt, bushing, washers, and NOTE: Horizontal endplate movement occurs
nut. Torque nut and install new cotter during a collective stick movement of
pin. approximately 25% to 65% collective stick
position as shown on the IIDS.
(3). Install wires in module block (Ref.
CSP-SPM).
(13). Move collective stick full up and then
(4). Install stabilizer test box (T1009) in left full down and visually make sure the
VSCS (Ref. Section 67-20-00). horizontal endplates move and VSCS
indicators show the same movement.
(5). Put analog multimeter (T1001) leads
into collective position jacks of stabil If collective position sensor link
izer test box (T1009) (Ref. Section CAUTION and collective position sensor
67-20-00). bellcrank go past center or become aligned,
the collective controls can become locked or
(6). Apply external electrical power, use position sensor can send an incorrect signal
ground power unit (T2002) (Ref. to the VSCS system.
CSP-900RMM-3).
Moving Flight Controls (14). Pull pilot collective friction release

switch and move collective stick to full
up position and make sure collective
position sensor link and collective
position sensor bellcrank do not go past
center or become aligned.
(7). Apply 1000 psig (6894.8 kPa) hydrau
lic pressure to hydraulic system (15). If necessary, adjust cockpit collective
number 1, use hydraulic mule (T2001) control tube and collective closet
(Ref. Section 29-00-00). controls rod to rotate collective position
sensor link and collective position
(8). Pull pilot collective friction release sensor bellcrank so they do not go past
switch and put collective stick full down center or become aligned. Do the
as shown on the IIDS. collective controls part of rotor flight
controls rigging verification.
(9). Loosen screws (23) and turn position
transducer to get an indication of +7.4
+/-0.2 volts on analog multimeter (16). Remove hydraulic pressure (Ref.
(T1001). Torque screws. Section 29-00-00).
(10). Remove multimeter and stabilizer test (17). Remove external electrical power (Ref.
box (Ref. Section 67-20-00). CSP-900RMM-3).
(11). Repeat steps (4). thru (8). for right

VSCS. (18). Install floor access panel AR138 (Ref.
Section 06-00-00).
(12). Make sure you get an indication of +7.4
+/-0.2 volts on analog multimeter (19). Install pilot crew seat (Ref. Section
(T1001). 25-10-00).
Page 410
14. Collective Lower Closet Bellcrank A. Collective Lower Closet Bellcrank

Assembly Bracket Assembly Removal
(Ref. Figure 402) (1). Remove collective lower closet bell
crank.
A. Collective Lower Closet Bellcrank
Assembly Removal (2). Remove collective position sensor
(1). Remove collective balance spring. assembly.
(2). Remove collective position sensor (3). Remove environmental seal from
assembly. around collective bellcrank bracket (48).
(3). Remove cotter pin (6) from bolt (30). (4). Remove bolts (4), washers (8), and
collective bracket (48).
and bolt (30). Remove lower closet B. Collective Lower Closet Bellcrank
bellcrank (26). Bracket Assembly Installation
B. Collective Lower Closet Bellcrank (1). Prepare mating surfaces of collective
Assembly Installation bracket and structure for electrical
bond (Ref. CSP-SPM).
(1). Install collective bellcrank, bolt,
washers, and nut. Torque nut and (2). Do a test on bellcrank bracket for Class
install new cotter pin. L electrical bond (Ref. CSP-SPM).
(2). Install collective balance spring. (3). Install bracket, bolts, and washers.
Torque bolts.
(3). Install collective position sensor
assembly. Sealant, Fuel Resistant (C216)
15. Collective Lower Closet Bellcrank
Bracket Assembly
(Ref. Figure 402)
(4). Environmentally seal bracket, use
Consumable Materials sealant (C216) (Ref. CSP-SPM).
(Ref. CSPSPM)
Item Nomenclature
(5). Install collective position sensor
assembly.
(6). Install collective lower closet bellcrank.
Page 411
6 3
7
8
2
48
1 8
43
7 11
6
43
51
9
28 8 17
3 PL 8
27
46
26 8 27
6 14 5 8 2 PL
15 29
19
8
7 11
8 8 REF. 43
7
12 7
10 6 20 24
6 20
8 25
16 6 REF. 33
18 11 REF. 11
6 13 31
11 (2 PL)
7 7
11 33 (2 PL)
TO COPILOT REF. 17
COLLECTIVE 21 11 (2 PL) 44
32 (2 PL) 30
8 5
6 47
50 7
6 11
11 REF. 17
7
REF. 43 34
38
22 35 REF. 31 VIEW ROTATED
REF. 25 8
8
8 7
45
36
6
8 42
REF. 44
7 37
6 REF. 26
8 8 8 40
41 23 49 (2 PL) 39 8
4 PL 9G67-021C
Figure 402. Pilot Collective Controls, Cockpit
Page 412

1. COLLECTIVE STICK BOOT 27. NUT
2. COLLECTIVE STICK ASSEMBLY 28. BOLT
3. COLLECTIVE UPPER CLOSET BELLCRANK 29. BOLT
4. BOLT 30. BOLT
5. SPRING ATTACH CLIP 31. BRACKET ASSEMBLY
7. NUT 33. BOLT
8. WASHER 34. MODULE BLOCK
9. BOLT 35. COLLECTIVE POSITION SENSOR ASSEMBLY
10. GROMMET 36. COLLECTIVE BALANCE SPRING
11. WASHER 37. TIEDOWN STRAP
12. COLLECTIVE LINK ASSEMBLY 38. RIGHT FORWARD SKID FITTING
13. BOLT 39. COLLECTIVE BALANCE SPRING BRACKET
14. COLLECTIVE STICK BRACKET ASSEMBLY 40. SCREW
15. SPACER 41. BOLT
16. COLLECTIVE STICK BELLCRANK ASSEMBLY 42. NUT
17. COCKPIT COLLECTIVE CONTROL TUBE ASSEMBLY 43. COLLECTIVE CLOSET CONTROL ROD ASSEMBLY
18. BOLT 44. COLLECTIVE SENSOR BELLCRANK ASSEMBLY
19. BOLT 45. BOLT
20. WASHER 46. BOLT
21. INTERCONNECT CONTROL ROD 47. COLLECTIVE SENSOR TRANSDUCER ASSEMBLY
22. BUSHING 48. CONTROLS UPPER DECK BELLCRANK BRACKET
23. SCREW 49. POTENTIOMETER CLAMP
24. BOLT 50. BOLT
25. SENSOR LINK ASSEMBLY 51. WASHER
26. COLLECTIVE LOWER CLOSET BELLCRANK
ASSEMBLY
16. Copilot (Quick Release) Collective B. Copilot (Quick Release) Collective

Control Stick (900 CONFIG) Control Stick (900 CONFIG) Installation
Make sure engine control pins
(Ref. Figure 403) CAUTION in collective control stick are in
alignment with collective stick base when
A. Copilot (Quick Release) Collective you install collective control stick.
Control Stick (900 CONFIG) Removal
(1). Install collective control stick in
(1). Remove collective stick boot (1). collective stick base.
(2). Remove access panel AL129 (Ref. (2). Push down and turn spring loaded
Section 06-00-00). collar, release spring loaded collar and
permit it to move up collective control
stick and engage lock mechanism.
(3). Disconnect electrical connector P2 (3).
(3). Install threaded collar on spring loaded
(4). Remove dust cap (26) from dust cap collar. Tighten threaded collar with
receptacle (35) and install on J141 (4). your hand.
(5). Remove threaded collar (22) from (4). Remove dust cap from J141 and install
spring loaded collar (23) and move up on dust cap receptacle (35).
collective control stick (31). (5). Connect electrical connector P2.
(6). Push down and turn spring loaded (6). Install access panel AL129 (Ref. Section
collar (23) to disengage lock mecha 06-00-00).
nism. (7). Install collective stick boot.
(7). Pull collective control stick (31) tube (8). Do the engine controls operational test
out of collective stick base (30). (Ref. Section 76-00-00).
Page 413
17. Copilot Collective Control Stick (2). Install collective control stick, bolts,
Assembly. washers, bonding jumper (inboard), and
nuts. Torque nuts and install new
(Ref. Figure 403) cotter pins.
(Ref. CSPSPM)
Item Nomenclature
C220 Compound, AntiSeize (3). Environmentally seal bonding jumper,
C701 Lockwire use sealant (C216) (Ref. CSP-SPM).
(4). Install collective link, bolt, washers,
A. Copilot Collective Control Stick and nut. Torque nut and install new
Assembly Removal cotter pin.
(1). Remove copilot crew seat (Ref. Section Compound, Anti-Seize (C220)
25-10-00).
(2). Remove collective stick boot (1).
(3). Remove access panels AL129 and
AL138 (Ref. Section 06-00-00). (5). Apply anti-seize compound (C220) to
threads of mechanical engine control
(4). Disconnect electrical connector P2 (3). collective stick fittings.
(5). Remove dust cap (26) from dust cap Be careful when you connect
receptacle (35) and install on J141 (4) CAUTION mechanical engine control
or J532 (28). cables. If you are not careful damage can oc
NOTE: Tag left and right mechanical engine cur.
control interconnect cables (17). (6). Connect mechanical engine control
Be careful when you disconnect cables. Torque cable end nuts 60-80 in
CAUTION mechanical engine control lb (6.78-9.04 Nm) and safety with
cables. If you are not careful, damage can lockwire (C701).
occur. (7). Remove dust cap from receptacle J141
(6). Disconnect mechanical engine control or J532.
interconnect cables (17). (8). Install dust cap on dust cap receptacle.
(7). Remove cotter pin (6), nut (7), washers (9). Connect electrical connector P2.
(11), and bolt (8).
(10). Test collective control stick for Class L
(8). Remove environmental seal from bolt electrical bond (Ref. CSP-SPM).
(18) inboard location only.
(11). Do the engine controls operational test
(9). Remove cotter pins (6), nuts (7), (Ref. Section 76-00-00).
washers (11), and bolts (18). Remove
collective control stick (2). (12). Install access panels AL129 and AL138
B. Copilot Collective Control Stick
Assembly Installation (13). Install collective stick boot.
(1). Prepare inner surface of inboard (14). Install copilot crew seat (Ref. Section
collective stick bracket to collective 25-10-00).
stick attach point and bonding jumper
for electrical bond (Ref. CSP-SPM). 18. Deleted
Page 414
19. Copilot (Quick Release) Collective Be careful when you disconnect

Control Stick (902 CONFIG) CAUTION mechanical engine control cable
assemblies. If you are not careful, damage
A. Copilot (Quick Release) Collective NOTE:

Control Stick (902 CONFIG) Removal Mark left and right mechanical engine
control interconnect cable assemblies
(1). Disconnect electrical connector P2 (27). (17).
(2). Install dust cap on receptacle J532 (28). If necessary, rotate collective stick grips
to disengage interconnect cables.
(3). Remove quick release pin (29).
(4). Remove and discard lockwire. Loosen
(4). Remove quick release collective control nuts at both ends of mechanical engine
stick (31) and o-ring (34). control cable assembly (17) Remove
cable assembly.
B. Copilot (Quick Release) Collective
B. Interconnect Cable Assemblies
Control Stick (902 CONFIG) Installation
Installation
(1). If necessary, install o-ring on collective Compound, Anti-Seize (C220)
control stick.
(2). Install collective stick into collective

base.
(3). Install quick release pin through (1). Apply anti-seize compound (C220) to
collective stick. threads of mechanical engine control
collective stick fittings.
(4). Remove dust cap from receptacle J532.
NOTE:
(5). Connect electrical connector P2. If necessary, rotate collective stick grips
to engage interconnect cables.
(6). Install cap on cap receptacle.
Adjust micro adjust adapters (25) to make
sure cables are installed without tension
20. Interconnect Cable Assemblies load.
(Ref. Figure 403) Be careful when you connect
CAUTION mechanical engine control
cables, damage to cables can occur.
(Ref. CSPSPM) (2). Connect mechanical engine control
Item Nomenclature interconnect cable. Torque cable end
C701 Lockwire nuts and jam nuts 60-80 in lb
C220 Compound, AntiSeize (6.78-9.04 Nm) and safety with
lockwire (C701).
A. Interconnect Cable Assemblies Removal (3). Do the Engine Controls Operational

Test (Ref. Section 76-00-00)
(1). Remove copilot crew seat assembly (4). Install access panels AL129, AL138,
(Ref. Section 25-10-00). B142 (Ref. Section 06-00-00).
(2). Remove copilot collective stick boot (1). (5). Install collective stick boot.
(3). Remove access panels AL129, AL138, (6). Install copilot crew seat (Ref. Section
and B142 (Ref. Section 06-00-00). 25-10-00).
Page 415
21. Collective Interconnect Control Rod B. Copilot Collective Link Assembly

(Ref. Figure 403) (1). Install bolt, washers, and nut attaching
lower end of collective link assembly to
A. Collective Interconnect Control Rod bellcrank assembly. Torque nut and
Assembly Removal install new cotter pin
(1). Remove copilot crew seat (Ref. Section (2). Install copilot collective control stick
25-10-00). assembly.
(2). Remove access panels AL138 and B142 23. Collective Bellcrank Assembly, Copilot
(Ref. Figure 403)
(3). Remove cotter pins (6), nuts (7),
washers (11), and bolts (9 and 13). A. Copilot Collective Bellcrank Assembly
Remove control rod (20). Removal
(1). Remove copilot collective link assembly
B. Collective Interconnect Control Rod
(12).
(1). Install bolts, washers, and nuts. Torque Remove nut (7), washers (11), and bolt
nuts and install new cotter pins (13) attaching collective interconnect
(2). Install access panels AL138 and B142 control rod assembly (20) to copilot
(Ref. Section 06-00-00). collective bellcrank assembly (16).
(3). Install copilot crew seat (Ref. Section Remove nut (7), washers (11), and bolt
25-10-00). (10) that attach bellcrank assembly (16)
to collective stick bracket assembly
22. Copilot Collective Link Assembly
(14). Remove bellcrank.
(Ref. Figure 403) B. Copilot Collective Bellcrank Assembly
A. Copilot Collective Link Assembly Installation
Removal (1). Install bolt, washers, and nut attaching
collective bellcrank assembly to copilot
(1). Remove copilot collective control stick
collective stick bracket assembly.
assembly (2).
Torque nut and install new cotter pin.
(2). Remove and discard cotter pin (6). (2). Install bolt, washers, and nut attaching
Remove nut (7), washers (11), and bolt collective interconnect control rod
(19) that attach lower end of collective assembly to bellcrank assembly. Torque
link assembly (12) to collective stick nut and install new cotter pin.
bellcrank assembly (16) Remove
collective link assembly. (3). Install copilot collective link assembly.
Page 416
24. Collective Stick Bracket Assembly, B. Copilot Collective Stick Bracket

Copilot Assembly Installation
(Ref. Figure 403) (1). Prepare mating surfaces of collective
stick bracket and structure for electri
(Ref. CSPSPM) (2). Install bolts and washers attaching
Item Nomenclature copilot collective bracket assembly to
C216 Sealant, Fuel Resistant airframe mounting structure. Torque
bolts.
A. Copilot Collective Stick Bracket Sealant, Fuel Resistant (C216)
Assembly Removal
(1). Remove copilot collective bellcrank
assembly (16).
(2). Remove copilot collective control stick (3). Fillet seal bracket assembly to airframe
assembly (2). mating structure using sealant (C216)
(Ref. CSP-SPM).
(3). Remove bolts (5 and 15) and washers
(11) that attach bracket assembly (14) (4). Test collective stick bracket assembly
to airframe. for class L electrical bond
(Ref. CSP-SPM).
(4). Remove fillet seal from around bracket
assembly Remove bracket. (5). Install collective bellcrank assembly.
Page 417
20
7 11
3
11 6
4 18
26
6
7 5 (2 PL)
11 11
9 6
11 (2 PL)
16 11 7
14 10
11
11
21
7 11 7
6 25
20 11 6
17 13
17 24 8
11
24 1
11
15 14 30
(3 PL)
11 12
(3 PL)
MECHANICAL ENGINE CONTROL 22
CABLE COUPLING (TYPICAL)
31
23
19 16 EARLY 900 CONFIG
11 11 6
7 9G67-022-1
Figure 403. Copilot Collective Controls, Cockpit (Sheet 1 of 2)
Page 418
29
31
27
28 VIEW ROTATED
34
35
30
33
902 CONFIG 9G67-022-2
1. COLLECTIVE STICK BOOT 18. BOLT

2. COLLECTIVE CONTROL STICK 19. BOLT
3. ELECTRICAL CONNECTOR (P2) 20. INTERCONNECT CONTROL ROD
4. ELECTRICAL RECEPTACLE J141 21. DUAL ROD END BEARING
5. BOLT 22. THREADED COLLAR
6. COTTER PIN 23. SPRING LOADED COLLAR
7. NUT 24. MECHANICAL ENGINE CONTROL CABLE NUT
8. BOLT 25. MICRO ADJUST ADAPTER
9. BOLT 26. DUST CAP
10. BOLT 27. ELECTRICAL CONNECTOR (P2)
11. WASHER 28. ELECTRICAL RECEPTACLE J532
12. COLLECTIVE LINK 29. QUICK RELEASE PIN
13. BOLT 30. COLLECTIVE STICK BASE
14. COLLECTIVE STICK BRACKET 31. COPILOT (QUICK RELEASE) COLLECTIVE STICK
15. BOLT 32. WIRE HARNESS W151
16. COLLECTIVE STICK BELLCRANK 33. WIRE HARNESS W153
17. MECHANICAL ENGINE CONTROLS INTERCONNECT 34. ORING
CABLES 35. DUST CAP RECEPTACLE
Figure 403. Copilot Collective Controls, Cockpit (Sheet 2 of 2)
Page 419
25. FS 157.730 Collective Bellcrank 26. Collective (Cabin) Control Rod Assembly
Assembly
(Ref. Figure 404)
(Ref. Figure 404)
A. Collective (Cabin) Control Rod Assembly
A. Collective Bellcrank Assembly Removal Removal
(1). Remove cabin interior roof panels
(1). Remove access panels L155, R155 and (Ref. Section 25-20-00).
T155 (Ref. Section 06-00-00).
(2). Remove roof panels Remove nuts (3), washers (4), and bolts
(Ref. Section 25-20-00). (5) attaching both ends of collective
cabin control rod assembly (7) to
(3). Remove FS 155.500 FOD cover (1). collective upper closet bellcrank
assembly (8) and collective upper deck
(4). Remove and discard cotter pins (2). bellcrank assembly (11). Remove
Remove nuts (3), washers (4), and bolts control rod.
(5) attaching collective closet control
rod assembly (6) and collective control B. Collective (Cabin) Control Rod Assembly
rod assembly (7) to FS 157.730 collec Installation
tive bellcrank assembly (8).
(1). Install bolts, washers, and nuts
(5). Remove and discard cotter pin (2).Re attaching both ends of collective cabin
move nut (3), washers (4), and bolt (10) control rod assembly to collective upper
attaching collective bellcrank assembly closet bellcrank assembly and collective
(8) to control deck bracket assembly (9). upper deck bellcrank assembly. Torque
nuts and install new cotter pins.
(6). Remove bellcrank assembly (8).
(2). Verify collective control system rigging.
B. Collective Bellcrank Assembly
(3). Install cabin interior roof panels (Ref.
Installation
Section 25-20-00).
NOTE: Adjustment of control rods might be re 27. Collective Upper Deck Bellcrank
quired for installation. Assembly
(1). Install bolt, washers, and nut attaching (Ref. Figure 404)
FS 157.730 collective bellcrank assem
bly to control deck bracket assembly. A. Collective Upper Deck Bellcrank
Assembly Removal
attaching collective closet control rod (1). Remove access panels L155, R155 and
assembly and collective control rod T155 (Ref. Section 06-00-00).
assembly to collective bellcrank (2). Remove roof panels (Ref. Section
assembly. 25-20-00).
(3). Verify collective control system rigging. (3). Remove collective/longitudinal FOD
(Ref. Section 67-10-00). cover (12).
(4). Torque nuts and install new cotter pins. (4). Remove and discard cotter pins (2).
Remove nuts (3), washers (4) and bolts
(5). Install FS 155.500 FOD cover. (5) attaching collective cabin control rod
assembly (7) and collective actuator
(6). Install roof panels control rod assembly (13) to collective
(Ref. Section 25-20-00). upper deck bellcrank assembly (11).
(7). Install access panels L155, R155 and (5). Remove and discard cotter pin (2).
T155 (Ref. Section 06-00-00). Remove nut (3), washers (4 and 14) and
Page 420
bolt (15) attaching bellcrank assembly B. Collective Bracket Assembly Installation

(11) to FS 170.877 collective bracket
assembly (16). (1). Install bolts and washers attaching FS
170.877 collective bracket assembly to
B. Collective Upper Deck Bellcrank upper deck surface. Torque bolts.
(2). Install collective upper deck bellcrank
assembly.
(1). Install bolt, washers, and nut attaching
collective upper deck bellcrank assem
bly to FS 170.877 collective bracket 29. Collective To Actuator Control Rod
assembly. Torque nut and install new Assembly
cotter pin.
(Ref. Figure 404)
(2). Install bolt, washers, and nut attaching A. Collective To Actuator Control Rod
collective cabin control rod assembly to Assembly Removal
upper deck bellcrank bellcrank assem
bly. Torque nut and install new cotter (1). Remove collective/longitudinal FOD
pin. cover.
(3). Verify collective control system rigging. (2). Remove and discard cotter pin (2).
Remove nut (3), washers (4), and bolt
(5) attaching control rod assembly (13)
(4). Install collective/longitudinal FOD to collective upper deck bellcrank
cover. assembly (11).
(5). Install bolt, washer, and nut attaching (3). Remove and discard cotter pin (2).
collective actuator control rod assembly Remove nut (3), washers (4), and bolt
to upper deck bellcrank assembly. (17) attaching control rod assembly (13)
Torque nut and install new cotter pin. to collective servoactuator (18).
(6). Install roof panels (Ref. Section B. Collective To Actuator Control Rod
25-20-00). Assembly Installation

(7). Install access panels L155, R155 and collective actuator control rod assembly
T155 (Ref. Section 06-00-00). to collective upper deck bellcrank
assembly and servoactuator. Torque
28. Collective Bracket Assembly FS
170.877
(2). Install collective/longitudinal FOD
cover.
(Ref. Figure 404)
Align actuator bearing with cle
CAUTION vis of control rod to prevent
A. Collective Bracket Assembly Removal
damage to bearing seal during control rod
attachment.
(1). Remove collective upper deck bellcrank
assembly. (3). Install bolt, washers, and nut attaching
control rod assembly to collective
(2). Remove bolts (19) and washers (20) servoactuator unit. Torque nut and
that attach FS 170.877 collective install new cotter pin.
bracket assembly (16) to mounting deck
surface Remove bracket. (4). Verify collective control system rigging.
Page 421
2
3
18 REF. 18
4
17
11 13
1 12 2 2
3 REF. 13
8 3
7 4 4
16 REF. 11
14
6
15 4
10 REF. 8
5 5
4 2
4 9 19 (4 PL) 4 3
2 4
2 REF. 7 4
20 (4 PL)
5
3
3 4
4
2 REF. 16
REF. 6 4 REF. 7 3
5
9G67-024A
1. FOD COVER FMU 155.500 12. FOD COVER COLLECTIVE/LONGITUDINAL

2. COTTER PIN 13. COLLECTIVE TO ACTUATOR CONTROL ROD
3. NUT ASSEMBLY
5. BOLT 15. BOLT
6. COLLECTIVE CLOSET CONTROL ROD ASSEMBLY 16. COLLECTIVE BRACKET ASSEMBLY FS 170.877
7. COLLECTIVE CONTROL ROD ASSEMBLY 17. BOLT
8. COLLECTIVE BELLCRANK ASSEMBLY FS 157.730 18. COLLECTIVE SERVOACTUATOR UNIT
9. CONTROL DECK BRACKET ASSEMBLY 19. BOLT
10. BOLT 20. WASHER
11. COLLECTIVE UPPER DECK BELLCRANK ASSEMBLY
Figure 404. Collective Controls, Upper Deck
30. Cyclic Stick Boot B. Cyclic Stick Boot Installation
(Ref. Figure 405)

(1). Slide cyclic stick boot down over cyclic
stick with hook and loop closure on
A. Cyclic Stick Boot Removal
forward side.
from cyclic stick boot (2). Slide boot up (2). Install screws and washers. Torque
over cyclic stick (1). screws.
Page 422
31. Cyclic Stick Assembly Sealant, Fuel Resistant (C216)
(Ref. Figure 405)
Consumable Materials (6). Environmentally seal bonding jumper

(Ref. CSPSPM) using sealant (C216) (Ref. CSP-SPM).
Item Nomenclature
NOTE: If converting to dual cyclic controls, re
C216 Sealant, Fuel Resistant move dust cap from receptacle J143 and
install onto dummy receptacle.
A. Cyclic Stick Assembly Removal (7). Attach electrical connector P1 to
receptacle J142 pilot or J143 copilot.
(1). Open access panel R128 or L109 (8). Test bonding jumper assembly for class
(Ref. Section 06-00-00). L electrical bond (Ref. CSP-SPM).
(9). Install cyclic control stick boot.
(2). Remove cyclic stick boot.
(10). Close access panel R128 or L109
(3). Detach electrical connector P1 (5) from (Ref. Section 06-00-00).
receptacle J142 pilot or J143 copilot.
32. Copilot (Quick Release) Cyclic Stick
Assembly
(4). Remove environmental seal from
bonding jumper (10) attachment. (Ref. Figure 405)
A. Copilot (Quick Release) Cyclic Stick
(5). Remove screw (12) and washer (11) Assembly Removal
attaching bonding jumper (10) to
airframe. NOTE: The copilot (quick release) cyclic stick
assembly consists of the boot, spring clips,
(6). Remove nuts (8), washers (9), and bolts and the cyclic stick as one unit..
(6) from longitudinal crank assembly (1). If necessary, open access panel L109
(7). (Ref. Section 06-00-00).
(7). Slide cyclic stick (1) forward from (2). Pull cyclic stick boot (2) hook and loop
longitudinal crank assembly (7). fastener from floor.
(3). Remove boot from around cyclic stick
B. Cyclic Stick Assembly Installation assembly (1).
(4). Detach electrical connector P1 (5) from
(1). Slide cyclic stick assembly aft onto
receptacle J143.
longitudinal crank assembly
(a). If autopilot is installed, remove
(2). Install bolts, washers, and nuts. jumper plug from adjacent dummy
receptacle and install it on J143.
(3). Torque nuts maintaining gap under (b). If autopilot is not installed, remove
washer at bolt head and at nut. Gap at protective cover from adjacent
one side shall not exceed two times the dummy receptacle and install it on
gap at the other side. J143.
(4). Prepare bonding jumper attach point (5). Disconnect (two piece) electrical bond
for electrical bond (Ref. CSP-SPM). jumper (10).
(6). If necessary, remove screw (12) and
(5). Attach bonding jumper to airframe washer (11) attaching bonding jumper
with screw and washer. Torque screw. (10) to airframe.
Page 423
(7). Remove two spring clips (21) from (7). Install cyclic stick boot over cyclic stick
longitudinal crank assembly (7). assembly.
NOTE: Do not close the spring clips after re (8). Press hook and loop fasteners together
moval. The spring clips must be stored in to secure against floor and close around
the open position. cyclic stick.
(8). Slide cyclic stick assembly (1) forward (9). If necessary, close access panel L109
from longitudinal crank assembly (7) (Ref. Section 06-00-00).
and remove.
33. Pilot Cyclic Stick Centering Strap
(9). Install copilot (quick release) cyclic (Ref. Figure 405)
stick floor cover. Ensure velcro is firmly
engaged. (Ref CSP-900IPL-4
Sec. 91-10-00). Consumable Materials
(Ref. CSPSPM)
B. Copilot (Quick Release) Cyclic Stick Item Nomenclature
Assembly Installation C402 Adhesive, Epoxy
(1). Remove copilot (quick release) cyclic
stick floor cover. A. Pilot Cyclic Stick Centering Strap
Removal
(2). Slide cyclic stick assembly aft into
longitudinal crank assembly (7). (1). Remove nut (14), washers (15 and 18),
radius blocks (16), and bolt (19)
(3). Install two spring clips thru longitudi attaching cyclic stick centering strap
nal crank assembly (7) and cyclic stick (13) to pilot cyclic stick assembly (1)
assembly (1). Remove strap.
(4). Attach electrical connector P1 (5) to B. Pilot Cyclic Stick Centering Strap
receptacle J143 copilot. Installation
(a). If autopilot is installed, remove (1). Align cyclic stick centering strap on
jumper plug from J143 and install on pilot cyclic stick assembly.
adjacent dummy receptacle.
(2). Install bolt, radius blocks, washers, and
(b). If autopilot is not installed, remove nut. Torque nut.
protective cover from J143 and Adhesive, Epoxy (C402)
install it on adjacent dummy recep
tacle.
(5). If necessary, install screw (12) and
washer (11) attaching bonding jumper
(10) to airframe. (3). Bond hook tape strap attachment (17)
with epoxy adhesive (C402) to pilot
(6). Connect (two piece) electrical bond cyclic stick at point where centering
jumper (10). strap attaches in stowed position.
Page 424
16
19
13 18
REF 13
17 16
15 14
1
VIEW
ROTATED REF 1
3 20
2
4
6
6
9
7
8
5 22-24 IN LB
2.4-2.7 Nm
10
11
12
9G67-054
Figure 405. Cyclic Stick Assembly (Sheet 1 of 2)
Page 425
20
23 22
5
24
10
11
12 21
OPEN CLOSED
COPILOT (QUICK RELEASE) CYCLIC STICK ASSEMBLY 9G67-061
Figure 405. Cyclic Stick Assembly (Sheet 2 of 2)
Page 426

1. CYCLIC STICK ASSEMBLY 12. SCREW
2. CYCLIC STICK BOOT ASSEMBLY 13. PILOT CYCLIC STICK CENTERING STRAP ASSEMBLY
3. SCREW 14. NUT
5. CONNECTOR P1 16. RADIUS BLOCK
6. BOLT 17. HOOK TAPE FASTENER HALF
7. CYCLIC BASE LONGITUDINAL CRANK ASSEMBLY 18. WASHER
8. NUT 19. BOLT
9. WASHER 20. CYCLIC BASE ASSEMBLY
10. ELECTRICAL BOND JUMPER 21. EXPANDABLE BOLTS (SPRING CLIPS)
11. WASHER
Page 427
34. Cyclic Base Lateral Control Tube 35. Lateral Dual Control Interconnect Control
Assembly Rod Assembly
(Ref. Figure 406)
(Ref. Figure 406)
A. Lateral Interconnect Control Rod
Assembly Removal
A. Cyclic Base Lateral Control Tube
Assembly Removal (1). Remove FS 144.775 longitudinal
bracket assembly.
(1). Remove FS 144.775 longitudinal (2). Remove copilot crew seat (Ref. Section
bracket assembly. 25-10-00).
(3). remove access panels AL138 and B142
(2). Remove and discard cotter pin (9). (Ref. Section 06-00-00).
Remove nut (10), washers (11) and bolt
(12) attaching lateral control tube (4). Remove and discard cotter pins (9).
assembly (13) to lateral crank assembly Remove nuts (10), washers (11), and
(30). bolts (15) that attach both ends of
lateral interconnect control rod assem
bly (8).
(3). DUAL CONTROLS - Remove and
discard cotter pin (9). Remove nut (10), B. Lateral Interconnect Control Rod
washers (11), and bolt (15) attaching Assembly Installation
lateral interconnect control rod assem (1). Install bolts, washers, and nuts
bly (8) to dual bearing rod end (7). attaching both ends of lateral intercon
nect control rod. Torque nuts and
(4). Remove and discard cotter pin (9). install new cotter pins.
(16) attaching dual bearing rod end (7) (2). Install FS 144.774 longitudinal bracket
to lateral bellcrank assembly (14). assembly.
(3). Verify lateral cyclic control system
B. Cyclic Base Lateral Control Tube rigging.
Assembly Installation (4). Install access panels AL138 and B142
(5). Install copilot crew seat (Ref. Section
lateral control tube assembly to cyclic
25-10-00).
base assembly.
36. Pilot Cyclic Base Assembly
(2). Install bolt, washers, and nut attaching (Ref. Figure 406)
dual bearing rod end to lateral bell
crank assembly. A. Pilot Cyclic Base Assembly Removal
(1). Remove cyclic stick assembly.
(3). DUAL CONTROLS - Install bolt, (2). Remove FS 144.775 longitudinal
washers, and nut attaching lateral bracket assembly.
interconnect control rod assembly to
dual bearing rod end. (3). Remove and discard cotter pin (9).
(4). Verify lateral cyclic control system (12) attaching lateral control tube
rigging, if required. assembly (13) to lateral crank(30).
Support cyclic base assembly
CAUTION during attach nut removal.
(5). Torque nuts and install new cotter pins.
(4). Remove nuts (3), washers (4), and bolts
(6). Install FS 144.774 longitudinal bracket (5) attaching cyclic base assembly (1) to
assembly. cockpit floor section.
Page 428
B. Cyclic Base Disassemble Lubricant, Solid Film (C101)

Remove nut (10), washers (11), second
ary stops (26), and bolt (25) attaching
longitudinal control rod assembly (18) (3). Apply solid film lubricant (C101) to
to longitudinal crank (6). threads of lateral crank assembly.
NOTE: Washers (21) are not retained and will (4). Install washer and nut attaching aft
become adrift. end of crank assembly to base assem
bly. Torque nut and install lockwire
(C702).
Remove nut (10), washers (11 and 21) (5). Install bolt, washers, and nut attaching
and bolt (22) attaching longitudinal forward end of lateral crank assembly
crank assembly (6) to lateral crank to base assembly. Torque nut and
assembly (30). install new cotter pin.
(3). Remove screws (28), washers (27) and (6). Install screws and washers attaching
bearing retainer (24). bearing retainer to base assembly.
Torque screws.
(4). Remove and discard cotter pin (9). NOTE: Untorqued gap between the two crank
Remove nut (10), washers (11 and 29) assemblies is 0.004-0.014 in
and bolt (23) attaching forward end of (0.1016-0.3556 mm). Add washers (21) as
lateral crank assembly (30) to base required. Maximum two washers.
assembly (1).
(5). Remove and discard safety wire. longitudinal crank assembly to lateral
Remove nut (20) and washer (19) crank assembly. Torque nut and install
attaching aft end of lateral crank (30) new cotter pin.
to base assembly (1).
(8). Install bolt, secondary stops, washers,
and nut attaching longitudinal control
(6). Separate base assembly (1) from crank rod assembly to longitudinal crank.
assembly (30). Torque nut and install new cotter pin.
C. Cyclic Base Reassemble D. Pilot Cyclic Base Assembly Installation

Consumable Materials through cyclic base assembly and
(Ref. CSPSPM) secure to floor section. Torque nuts.
Item Nomenclature
C101 Lubricant, Solid Film lateral control rod. Torque nut and
C702 Lockwire install new cotter pin.
(3). Install FS 144.774 longitudinal bracket

assembly.
(1). Inspect all components of cyclic base
and crank assemblies.
(4). Install pilot cyclic stick.
(2). Install lateral crank assembly into (5). Verify lateral and longitudinal controls
cyclic base assembly. system rigging.
Page 429
1
4
6 3 18 15 16
11 10 14
9 9
11
10 11
11 11
11 23 12 11
26 13
28 (4 PL) 1 7 9
11 10 17
27 (4 PL)
29 10 9
10 11
9 11
REF 18 15
19 20
9
30 8 11 10
24 80-90 IN LB
11 9.03-10.16 Nm
26
22 11
25
9
11
10
6 21 (2 PL)
9G67-055
1. CYCLIC BASE ASSEMBLY 16. BOLT

2. FS 144.774 LONGITUDINAL BRACKET ASSEMBLY 17. COPILOT CYCLIC BASE LATERAL CRANK ASSEMBLY
3. NUT 18. CYCLIC STICK LONGITUDINAL CONTROL ROD
4. WASHER ASSEMBLY
5. BOLT 19. WASHER
6. CYCLIC BASE LONGITUDINAL CRANK ASSEMBLY 20. NUT
7. DUAL ROD END BEARING 21. WASHER
8. DUAL CONTROL INTERCONNECT CONTROL ROD 22. BOLT
ASSEMBLY 23. BOLT
9. COTTER PIN 24. BEARING RETAINER
10. NUT 25. BOLT
11. WASHER 26. LONGITUDINAL SECONDARY STOP
12. BOLT 27. WASHER
13. CYCLIC BASE LATERAL CONTROL TUBE ASSEMBLY 28. SCREW
14. LATERAL BELLCRANK ASSEMBLY 29. WASHER
15. BOLT 30. CYCLIC BASE LATERAL CRANK ASSEMBLY
Figure 406. Cyclic Base Assembly
Page 430
37. Lateral Bellcrank Assembly (2). Install bolts and washers attaching
lateral bracket assembly. Torque bolts.
(Ref. Figure 407)
(3). Test lateral bracket assembly for class
A. Lateral Bellcrank Assembly Removal R electrical bond (CSP-SPM).
(1). Remove FS 144.775 longitudinal (4). Install lateral bellcrank assembly.
bracket assembly.
39. Lateral Gradient Spring Assembly
Remove nut (13), washers (14), and bolt (Ref. Figure 407)
(15) attaching dual bearing rod end (11)
and lateral controls tube assembly (2) A. Lateral Gradient Spring Assembly
to lateral bellcrank assembly (3). Removal
(3). Remove and discard cotter pin (12). (1). Remove FS 144.775 longitudinal
Remove nut (13), washers (14), and bolt bracket assembly.
to bellcrank assembly (3).
(4). Remove and discard cotter pin (12). (20) attaching lateral gradient spring
Remove nut (13), washers (14), and bolt assembly (6) to lateral trim actuator
(17) attaching bellcrank assembly (3) to crank (4).
lateral bracket assembly (5). (3). Remove and discard cotter pin (12).
B. Lateral Bellcrank Assembly Installation Remove nut (13), washers (14), and bolt
(33) attaching gradient spring (6) to
(1). Install bolt, washers, and nut attaching lateral bellcrank assembly (8).
lateral bellcrank assembly to lateral
bracket assembly. B. Lateral Gradient Spring Assembly
Installation
control rod assembly to bellcrank. (1). Install bolt, washers, and nut attaching
lateral gradient spring assembly to
(3). Install bolt, washers, and nut attaching lateral bellcrank assembly. Torque nut
dual ball bearing rod end and tube and install new cotter pin.
assembly to bellcrank.
(4). Torque nuts and install new cotter pins. gradient spring to lateral trim actuator
crank. Torque nut.
(5). Install FS 144.774 longitudinal bracket
assembly. (3). Install FS 144.775 longitudinal bracket
assembly.
38. Lateral Bracket Assembly
40. Lateral Trim Actuator Crank Assembly
(Ref. Figure 407)
(Ref. Figure 407)
A. Lateral Bracket Assembly Removal
A. Lateral Trim Actuator Crank Assembly
(1). Remove lateral bellcrank assembly. Removal
(2). Remove bolts (19) and washers (18) (1). Remove FS 144.775 longitudinal
attaching bracket assembly (5). bracket assembly.
B. Lateral Bracket Assembly Installation (2). Remove and discard cotter pin (12).
(1). Prepare bellcrank bracket and fuselage (20) attaching lateral gradient spring
structure mounting surfaces for (6) to lateral trim actuator crank
electrical bond (CSP-SPM). assembly (4).
Page 431
(3). Remove nut (21), washer (14), and bolt (3). Attach electrical connector P146 to the
(22) that attach crank assembly (4) to actuator assembly.
lateral trim actuator shaft (23).
(4). Install lateral trim actuator crank
B. Lateral Trim Actuator Crank Assembly assembly.
Installation
(5). Verify cyclic trim actuator operation
NOTE: Line up rigging holes in crank assembly (Ref. Rotor Flight Control System
and lateral trim actuator. Operational Test).
(1). Slide trim actuator crank onto actuator 42. Lateral Lower Closet Bellcrank Assembly
shaft and install bolt, washer, and nut.
Torque nut. (Ref. Figure 407)
(2). Install bolt, washers, and nut attaching A. Lateral Lower Closet Bellcrank Assembly
lateral gradient spring to lateral trim Removal
actuator crank. Torque nut and install (1). Remove pilot crew seat (Ref. Section
new cotter pin. 25-10-00).
(3). Install FS 144.775 longitudinal bracket (2). Remove access panel AR138 (Ref.
assembly. Section 06-00-00).
41. Lateral Trim Actuator Assembly (3). Remove insulation and controls closet
panels behind right crew seat (Ref.
A. Trim Actuator Assembly Removal (4). Remove and discard cotter pin (12).
(1). Remove lateral trim actuator crank (33) attaching lateral gradient spring
assembly. (6) to lateral bellcrank assembly (8).
(2). Detach electrical connector P146 from (5). Remove and discard cotter pin (12).
lateral trim actuator assembly (25). Remove nut (13), washers (14), and bolt
NOTE: Washers (24) are not retained and will to bellcrank assembly (8).
become adrift.
(3). Remove bolts (27 and 28) and washers Remove nut (13), washers (14), and bolt
(26 and 24) attaching actuator assem (34) attaching closet control rod
bly (25). assembly (9) to bellcrank assembly (8).
B. Trim Actuator Assembly Installation (7). Remove and discard cotter pin (12).
NOTE: Trim resistors are required for -103 and (29) that attach bellcrank assembly (8)
-105 trim actuators. If actuators -107 or
to bellcrank bracket assembly (8).
later are installed, trim resistors are to be
removed from RH forward avionics bay. B. Lateral Lower Closet Bellcrank Assembly
Installation
(1). Prepare trim actuator and fuselage
structure mounting surfaces for (1). Install bolt, washers, and nut attaching
electrical bond (CSP-SPM). lateral bellcrank assembly to lateral
controls bracket assembly.
NOTE: Install washers (24) between lateral
trim actuator and mounting surface. (2). Install bolt, washers, and nut attaching
control rod assembly to bellcrank.
(2). Install bolts and washers attaching
lateral trim actuator assembly to (3). Install bolt, washers, and nut attaching
mounting surface. Torque bolts. closet control rod assembly to bellcrank.
Page 432
(4). Install bolt, washers, and nut attaching 44. Lateral Closet Control Rod Assembly
lateral gradient spring to bellcrank.
(Ref. Figure 407)
rigging. A. Lateral Control Rod Removal
(6). Torque nuts and install new cotter pins. (1). Remove pilot crew seat (Ref. Section
25-10-00).
(7). Install controls closet and insulation If
dual controls are installed, panels (2). Remove access panel AR138 (Ref.
behind right crew seat (Ref. Section Section 06-00-00).
25-10-00).
(8). Install access panel AR138 (Ref. panels behind right crew seat (Ref.
Section 06-00-00). Section 25-10-00).
(9). Install pilot crew seat (Ref. Section (4). Remove and discard cotter pin (12).
25-10-00). Remove nut (13), washers (14), and bolt
(34) that attach lower end of lateral
43. Lateral Lower Closet Bellcrank Bracket
closet control rod assembly (9) to lateral
Assembly
lower closet bellcrank assembly (8).
(Ref. Figure 407)
A. Lateral Lower Closet Bracket Assembly Remove nut (13), washers (14), and bolt
Removal (35) attaching closet lateral control rod
assembly (9) to lateral closet upper
(1). Remove lateral lower closet bellcrank bellcrank assembly (36).
assembly.
B. Lateral Control Rod Installation
(2). Remove nuts (21), washers (14), and
bolts (30 and 31) attaching bracket (1). Install bolt, washers, and nut attaching
assembly (7). lateral closet control rod assembly to
lateral upper closet bellcrank. Torque
(3). Remove bolt (30) and washer (14)
attaching bracket assembly (7).
B. Lateral Lower Closet Bracket Assembly (2). Install bolt, washers, and nut attaching
Installation lateral closet control rod assembly to
lateral lower closet bellcrank assembly.
(1). Prepare lateral bracket and fuselage Torque nut and install new cotter pin.
structure mounting surfaces for
electrical bond (CSP-SPM). (3). Verify lateral cyclic control system
rigging.
attaching bracket assembly to mount (4). Install controls closet and insulation
ing surface. Torque nuts. panels behind right crew seat (Ref.
Section 25-10-00).
(3). Install bolt and washer attaching
bracket assembly to mounting surface. (5). Install access panel AR138
Torque bolt. (Ref. Section 06-00-00).
(4). Install lateral lower closet bellcrank (6). Install pilot crew seat (Ref. Section
Page 433
1
10
8
7
6
17
5
16
2 14
4
3 14
25 15 REF 3 REF 10
19 (4 PL)
18 (4 PL)
14 REF 5
REF 2 14
11
13 14
14 12 13
13
12 12
28 (2 PL)
27 (2 PL)
26 (2 PL) 26 (2 PL)
12
REF 6
13
14
REF 4
14
20
14 21
REF 25 23
24 (4 PL) 22
9G67-003-1B
Figure 407. Cockpit Lateral Cyclic Controls (Sheet 1 of 2)
Page 434
35
36
14
FS 148.00 BULKHEAD
21 14
14
12
REF 7
31
13 12
14
13 REF 8
13
14 12
14
21 12 REF 9
14
14 29
13
14
REF 10
14 (3 PL) 30 (3 PL) 32
13
VIEW LOOKING FORWARD 14 14
12
33 14
14 34
REF 6 9G67-003-2D
1. CYCLIC STICK BASE ASSEMBLY 19. BOLT
2. CYCLIC BASE LATERAL CONTROL TUBE ASSEMBLY 20. BOLT
3. LATERAL BELLCRANK ASSEMBLY 21. NUT, SELF LOCKING
4. LATERAL TRIM ACTUATOR CRANK ASSEMBLY 22. BOLT
5. LATERAL BELLCRANK BRACKET ASSEMBLY 23. LATERAL TRIM ACTUATOR OUTPUT SHAFT
6. LATERAL FORCE GRADIENT SPRING ASSEMBLY 24. WASHER
7. LATERAL CLOSET BELLCRANK BRACKET ASSEMBLY 25. LATERAL TRIM ACTUATOR ASSEMBLY
8. LATERAL CLOSET LOWER BELLCRANK ASSEMBLY 26. WASHER
9. LATERAL CLOSET CONTROL TUBE ASSEMBLY 27. BOLT
10. LATERAL FORE AND AFT CONTROL TUBE ASSEMBLY 28. BOLT
11. LATERAL DUAL BEARING ROD END 29. BOLT
13. NUT 31. BOLT
14. WASHER 32. BOLT
15. BOLT 33. BOLT
16. BOLT 34. BOLT
17. BOLT 35. BOLT
18. WASHER 36. LATERAL CLOSET UPPER BELLCRANK ASSEMBLY
Figure 407. Cockpit Lateral Cyclic Controls (Sheet 2 of 2)
Page 435
45. Upper Closet Lateral Bellcrank Assembly (5). Install FOD cover (FS 155.500).
(Ref. Figure 408) (6). Install roof panels (Ref. Section
25-20-00).
A. Upper Closet Lateral Bellcrank Assembly
Removal (7). Install controls closet and insulation
(1). Open access panels R155 and R210 panels behind right crew seat (Ref.
(Ref. Section 06-00-00). Section 25-10-00).
(2). Remove insulation and controls closet (8). Close access panels R155 and R210
panels behind right crew seat (Ref. (Ref. Section 06-00-00).
Section 25-10-00).
46. Lateral Deck Control Rod Assembly
(3). Remove roof panels (Ref. Section
25-20-00). (Ref. Figure 408)
(4). Remove FOD cover (FS 155.500). A. Lateral Deck Control Rod Assembly
Removal
Remove nut (2) washers (3), and bolt (4) (1). Remove roof panels (Ref. Section
that attach closet lateral control rod 25-20-00).
assembly (15) to upper closet lateral
bellcrank assembly (5). (2). Remove and discard cotter pin (1).
Remove nut (2), washers (3) and bolt (6)
(6). Remove and discard cotter pin (1). that attach lateral deck control rod
Remove nut (2), washers (3) and bolt (6) assembly (9) to upper closet lateral
that attach lateral deck control rod bellcrank assembly (5).
assembly (9) to bellcrank (5).
(7). Remove and discard cotter pin (1). Remove nut (2), washers (3) and bolt
Remove nut (2), washers (3) and bolt (7) (14) that attach control rod (9) to FS
that attach bellcrank (5) to bracket 165.588 bellcrank assembly (13).
assembly (8).
B. Lateral Deck Control Rod Assembly
B. Upper Closet Lateral Bellcrank Assembly
Installation
Installation
(1). Install bolt, washers, and nut attaching (1). Install bolt, washers, and nut attaching
upper closet lateral bellcrank assembly lateral deck control rod assembly to FS
to deck control bracket assembly. 165.588 bellcrank assembly. Torque nut
and install new cotter pin.
lateral deck control rod assembly to (2). Install bolt, washers, and nut attaching
bellcrank. control rod to bellcrank. Torque nut and
lateral control rod assembly to bell (3). Verify lateral cyclic control system
crank. rigging.
(4). Torque all nuts and install new cotter (4). Install roof panels (Ref. Section
pins. 25-20-00).
Page 436
47. FS 165.588 Lateral Bellcrank Assembly (3). Install bolt, washers, and nut attaching
lateral controls link assembly to
(Ref. Figure 408) bellcrank.
A. Lateral Bellcrank Assembly Removal
(1). Open access panel L155 (Ref. Section rigging.
06-00-00).
25-20-00). (6). Install roof panels (Ref. Section
25-20-00).
(7). Close access panel L155 (Ref. Section
(14) that attach lateral deck control rod
06-00-00).
assembly (9) to FS 165.588 bellcrank
assembly (12).
48. FS 165.588 Lateral Bracket Assembly
Remove nut (2), washers (3), and bolt (Ref. Figure 408)
(16) that attach lateral controls link
assembly (17) to bellcrank (13). A. Lateral Bracket Assembly Removal
(5). Remove and discard cotter pin (1). (1). Remove FS 165.588 lateral bellcrank
Remove nut (2), washers (3), and bolt assembly.
(10) that attach bellcrank (13) to lateral
bracket assembly (12). (2). Remove bolts (11) and washers (3) that
attach lateral bracket assembly (12).
B. Lateral Bellcrank Assembly Installation
(1). Install bolt, washers, and nut attaching B. Lateral Bracket Assembly Installation
FS 165.588 bellcrank assembly to
lateral bracket assembly. (1). Install bolts and washers attaching
lateral bracket assembly. Torque bolts.
lateral deck control rod assembly to (2). Install FS 165.588 lateral bellcrank
bellcrank. assembly.
Page 437
15 4
5
3
3
1
9
2
3
2 1
1
2
7 10
11 3
3
3
3 6 12
3
13
3 16
2
3
3
17
1
3
8 2
1
14 3
2
1
9G67-004D

2. NUT 11. BOLT
3. WASHER 12. LATERAL BRACKET ASSEMBLY
4. BOLT 13. LATERAL BELLCRANK ASSEMBLY FS 165.588
5. UPPER CLOSET LATERAL BELLCRANK ASSEMBLY 14. BOLT
6. BOLT 15. LATERAL CLOSET CONTROL TUBE
7. BOLT 16. BOLT
8. DECK CONTROL BRACKET ASSEMBLY 17. LATERAL CONTROLS LINK ASSEMBLY
9. LATERAL DECK CONTROL ROD ASSEMBLY
Figure 408. Upper Deck Lateral Cyclic Controls

49. Lateral Control Link Assembly (12) that attach link (15) to FS 170.536
lateral bellcrank assembly (11).
(Ref. Figure 409)
B. Lateral Control Link Assembly
A. Lateral Control Link Assembly Removal Installation
(1). Remove roof panels (Ref. Section (1). Install bolt, washers, and nut attaching
25-20-00). lateral control link assembly to FS
170.536 lateral bellcrank assembly.
(2). Remove and discard cotter pin (2). (2). Install bolt, washers, and nut attaching
Remove nut (3), washers (4), and bolt link assembly to FS 165.588 lateral
(14) that attach lateral control link bellcrank assembly.
assembly (15) to FS 165.588 lateral
bellcrank assembly (16). (3). Torque nuts and install new cotter pins.
(3). Remove and discard cotter pin (2). (4). Install roof panels (Ref. Section
Remove nut (3), washers (4) and bolt 25-20-00).
Page 438
50. FS 170.536 Lateral Bellcrank Assembly 51. Lateral Actuator Control Rod Assembly
A. Lateral Bellcrank Assembly Removal A. Lateral Actuator Control Rod Assembly
Removal
(1). Open access panels L155 and L210
(Ref. Section 06-00-00). (1). Open access panels L155 and L210
25-20-00). (2). Remove roof panels (Ref. Section
25-20-00).
(3). Remove lateral FOD cover.
(3). Loosen hose clamp on lateral upper
(4). Remove and discard cotter pin (2). deck control rod boot.
(12) that attach lateral control link (4). Remove and discard cotter pin (2).
assembly (15) to FS 170.536 lateral Remove nut (3), washers (4) and bolt
bellcrank assembly (11). (12) that attach lateral to actuator
control rod assembly (6) to FS 170.536
(5). Remove and discard cotter pin (2). lateral bellcrank assembly (11).
(12) that attach lateral actuator control (5). Remove and discard cotter pin (2).
rod assembly (6) to bellcrank (11). Remove nut (3), washers (4) and bolt (5)
that attach control rod assembly (6) to
(6). Remove and discard cotter pin (2). lateral servoactuator unit (1).
(8) that attach bellcrank (11) to FS B. Lateral Actuator Control Rod Assembly
170.536 lateral bracket assembly (7). Installation
B. Lateral Bellcrank Assembly Installation CAUTION
Care should be taken to align
actuator bearing with mating
(1). Install bolt, washers, and nut attaching clevis of control rod to prevent damage to
FS 170.536 lateral bellcrank assembly bearing seal during control rod attachment.
to FS 170.536 lateral bracket assembly.
(2). Install bolt, washers, and nut attaching lateral to actuator control rod assembly
lateral to actuator control rod assembly to lateral servoactuator unit.
to bellcrank.
(3). Install bolt, washer, and nut attaching control rod assembly to FS 170.536
lateral control link assembly to bell lateral bellcrank assembly.
crank.
(4). Verify lateral cyclic control system rigging.
rigging.
(5). Install roof panels (Ref. Section
(6). Install lateral FOD cover. 25-20-00).
(7). Install roof panels (Ref. Section (6). Tighten hose clamp on lateral upper
25-20-00). deck control rod boot.
(8). Close access panels L155 and L210 (7). Close access panels L155 and L210
Page 439
52. FS 170.536 Lateral Bracket Assembly B. Lateral Bracket Assembly Installation

(Ref. Figure 409)
(1). Install bolts and washers attaching FS
A. Lateral Bracket Assembly Removal 170.536 lateral bracket assembly to
mounting surface. Torque bolts.
(1). Open access panels L155 and L210
(2). Install lateral bellcrank assembly.
25-20-00).
(3). Remove lateral bellcrank assembly. 25-20-00).
(4). Remove bolts and washers attaching
FS 170.536 lateral bracket assembly (7) (4). Close access panels L155 and L210
to mounting surface. (Ref. Section 06-00-00).
3
1
2
4
4 5
6
2 3
4
7
9
10
4
2 8
3
14 4 11
2
3 4
16 4 12
4
4
2
4 15 13
3
9G67-056
1. LATERAL SERVOACTUATOR INPUT 9. BOLT

3. NUT 11. LATERAL BELLCRANK ASSEMBLY FS 170.536
4. WASHER 12. BOLT
5. BOLT 13. BOLT
6. LATERAL ACTUATOR CONTROL ROD ASSEMBLY 14. BOLT
7. LATERAL BRACKET ASSY BRACKET FS 170.536 15. LATERAL CONTROL LINK ASSEMBLY
8. BOLT 16. BELLCRANK ASSEMBLY FS 165.588
Figure 409. Upper Deck Lateral Servoactuator Controls
Page 440
53. Longitudinal Trim Actuator Assembly (7). Torque nut and install new cotter pin.
(Ref. Figure 410) (8). Install access panel AR138 and close
access panel R128 (Ref. Section
A. Trim Actuator Assembly Removal 06-00-00).
(1). Remove pilot crew seat (Ref. Section (9). Install pilot crew seat (Ref. Section
25-10-00). 25-10-00).
(2). Remove access panel AR138 and open 54. Longitudinal Trim Actuator Crank
access panel R128 (Ref. Section Assembly
06-00-00).
(Ref. Figure 410)
Remove nut (2), washers (3), and bolt A. Longitudinal Trim Actuator Crank
(4) that attach longitudinal gradient Assembly Removal
spring assembly (5) to longitudinal trim
actuator crank assembly (7). (1). Remove pilot crew seat (Ref. Section
25-10-00).
(4). Detach electrical connector P144 from
(2). Remove access panel AR138 and open
longitudinal trim actuator assembly (8).
access panel R128 (Ref. Section
(5). Remove bolts (11 and 12) and washers 06-00-00).
(13, 14 and 56) that attach actuator (3). Remove and discard cotter pin (1).
assembly (8) to mounting surface.
B. Trim Actuator Assembly Installation (4) that attach longitudinal gradient
spring (5) to longitudinal trim actuator
NOTE: Trim resistors are required for -103 and crank assembly (7).
-105 trim actuators. If actuators -107 or
later are installed, trim resistors are to be (4). Remove nut (6), washer (14) and bolt
removed from RH forward avionics bay. (48) and slide crank assembly (7) off of
longitudinal trim actuator (8) shaft.
CSP-SPM). B. Longitudinal Trim Actuator Crank
(2). Install bolts, washers attaching
longitudinal trim actuator assembly to
NOTE: Line up rigging holes while sliding
mounting surface. Torque bolts. crank onto trim actuator shaft.
(1). Slide longitudinal trim actuator crank
(3). Attach electrical connector P144 to
assembly onto longitudinal trim
actuator assembly.
actuator shaft. Torque nut.
(4). Verify cyclic trim actuator operation (2). Install bolt, washers, and nut attaching
(Ref. Rotor Flight Control System longitudinal gradient spring to crank.
Operational Test).
(3). Torque nut and install new cotter pin.
longitudinal gradient spring assembly (4). Install access panel AR138 and close
to longitudinal trim actuator crank access panel R128 (Ref. Section
(6). Verify longitudinal cyclic control system (5). Install pilot crew seat (Ref. Section
rigging. 25-10-00).
Page 441
55. Longitudinal Gradient Spring Assembly 56. FS 144.775 Longitudinal Bellcrank

Assembly
(Ref. Figure 410)
(Ref. Figure 410)
A. Longitudinal Gradient Spring Removal
A. Longitudinal Bellcrank Assembly
(1). Remove pilot crew seat (Ref. Section Removal
25-10-00).
(2). Remove access panel AR138 and open 25-10-00).
access panel R128 (Ref. Section (2). Remove access panel AR138
06-00-00). (Ref. Section 06-00-00).
(3). Remove insulation and controls closet (3). Remove and discard cotter pins (1).
panels behind right crew seat (Ref. Remove nuts (2), washers (3), and bolts
Section 25-10-00). (25) that attach longitudinal intercon
nect control rod assembly (53), FS
(4). Remove and discard cotter pin (1). 132.900 longitudinal control rod
Remove nut (2), washers (3), and bolt assembly (31) and longitudinal aft
(4) that attach longitudinal gradient cockpit control rod assembly (15) to
spring assembly (5) to longitudinal trim longitudinal bellcrank assembly (29).
actuator crank assembly (7).
(5). Remove and discard cotter pin (1). Remove nut (26), washers (14 and 28)
Remove nut (2), washers (3) and bolt (9) and bolt (27) that attaches bellcrank
that attach gradient spring (5) to FS assembly (29) to FS 144.775 longitudi
150.064 longitudinal bellcrank assem nal bracket assembly (24).
bly (10).
B. Longitudinal Bellcrank Assembly
B. Longitudinal Gradient Spring Installation Installation
(1). Install bolt, washers, and nut attaching (1). Install bolt, washers, and nut attaching
longitudinal gradient spring to longitu longitudinal bellcrank assembly to FS
dinal trim actuator crank assembly. 144.775 longitudinal bracket assembly.
(2). Install bolt, washers, and nut attaching (2). Install bolts, washers, and nuts
gradient spring to FS 150.064 longitu attaching longitudinal interconnect
dinal bellcrank assembly. control rod assembly, FS 132.900
longitudinal control rod assembly and
(3). Torque nuts and install new cotter pins. longitudinal aft cockpit control rod
assembly to bellcrank assembly.
panels behind right crew seat (Ref. (3). Verify longitudinal cyclic control system
Section 25-10-00). rigging.
(5). Install access panel AR138 and close
access panel R128 (Ref. Section (5). Install access panel AR138 (Ref.
06-00-00). Section 06-00-00).
(6). Install pilot crew seat (Ref. Section (6). Install pilot crew seat (Ref. Section
25-10-00). 25-10-00).
Page 442
57. FS 150.064 Longitudinal Bellcrank dinal closet control rod assembly to

Assembly bellcrank assembly.
(Ref. Figure 410) (3). Install bolt, spacer, washers, balance
spring clip, and nut attaching balance
A. Longitudinal Bellcrank Assembly spring cable assembly to bellcrank
Removal assembly.
(1). Remove pilot crew seat (Ref. Section (4). Install bolts, washers, and nuts
25-10-00). attaching longitudinal gradient spring
and longitudinal aft cockpit control rod
(2). Remove access panel AR138 (Ref. assembly to bellcrank assembly.
Section 06-00-00). (5). Verify longitudinal cyclic control system
rigging.
panels behind right crew seat (Ref. (6). Torque nuts and install new cotter pins.
Section 25-10-00).
(4). Remove and discard cotter pins (1). panels behind right crew seat (Ref.
Remove nuts (2), washers (3) and bolts Section 25-10-00).
(9) that attach longitudinal gradient (8). Install access panel AR138 (Ref.
spring (5) and longitudinal aft cockpit Section 06-00-00).
longitudinal bellcrank assembly (10). (9). Install pilot crew seat (Ref. Section
25-10-00).
Remove nut (17), washers (18, 19 and 58. FS 150.064 Longitudinal Bracket
45), spacer (20), bolt (21) and balance Assembly
spring clip (46) that attach balance (Ref. Figure 410)
spring cable assembly (22) to bellcrank
assembly (10). A. Longitudinal Bracket Assembly Removal
(6). Remove and discard cotter pin (1). 25-10-00).
Remove nut (2), washers (3), bolt (32),
grommet (33) and spacer (34) that (2). Remove access panel AR138 (Ref.
attach the lower end of longitudinal Section 06-00-00).
closet control rod (35) to bellcrank
assembly (10).
panels behind right crew seat (Ref.
(7). Remove and discard cotter pin (1). Section 25-10-00).
Remove nut (2), washers (14) and bolt (4). Remove lower closet directional
(9) that attach bellcrank assembly (10) bellcrank assembly (Ref. Section
to FS 150.064 longitudinal bracket 67-20-00).
assembly (16).
(5). Remove FS 150.064 longitudinal
(8). Remove bellcrank assembly (10). bellcrank assembly.
B. Longitudinal Bellcrank Assembly (6). Remove bolts (23) and bolt (47) and
Installation washers (3) and nuts (6) that attach FS
150.064 longitudinal bracket assembly
(1). Install bolt, washers, and nut attaching (16) to FS 144.775 longitudinal bracket
FS 150.064 longitudinal bellcrank assembly (24).
assembly to FS 150.064 longitudinal B. Longitudinal Bracket Assembly
bracket assembly. Installation
(2). Install bolt, spacer, grommet, washers, (1). Align FS 150.064 longitudinal bracket
and nut attaching lower end of longitu assembly with FS 144.775 longitudinal
Page 443
bracket assembly and install bolts, bolt, (9). Remove bolt (4), washers (3) and nuts
washers, and nuts. (6) that attach bracket assembly (24) to
mounting surface.
(2). Install FS 150.064 longitudinal bell
crank assembly. B. Longitudinal Bracket Assembly
Installation
(3). Install lower closet directional bell
crank assembly. (1). Prepare surface for electrical bond (Ref.
CSP-SPM).
(4). Torque nuts.
(5). Install controls closet and insulation FS 144.775 longitudinal bracket
panels behind right crew seat (Ref. assembly.
Section 25-10-00). (3). Install bolt, washers, and nut attaching
(6). Install access panel AR138 (Ref. FS 144.775 longitudinal bellcrank
Section 06-00-00). assembly to bracket assembly.
(4). Install bolts, bolt, washers, and nuts
(7). Install pilot crew seat (Ref. Section attaching FS 150.064 longitudinal
25-10-00). bracket assembly to FS 144.775
59. FS 144.775 Longitudinal Bracket longitudinal bracket assembly.
Assembly (5). Torque nuts and install new cotter pins.
(Ref. Figure 410) (6). Install FS 150.064 longitudinal bell
crank assembly.
A. Longitudinal Bracket Assembly Removal
(7). Install FS 150.164 lateral controls
(1). Remove pilot crew seat (Ref. Section bracket assembly.
25-10-00).
(8). Install lower closet directional bell
(2). Remove access panel AR138 (Ref. crank assembly (Ref. Section
Section 06-00-00). 67-20-00).
(3). Remove insulation and controls closet (9). Install controls closet and insulation
panels behind right crew seat (Ref. panels behind right crew seat (Ref.
Section 25-10-00). Section 25-10-00).
(10). Install access panel AR138 (Ref.
Section 06-00-00).
bellcrank assembly.
(5). Remove bolts (23) and bolt (47) and 25-10-00).
washers (3) and nuts (6) that attach FS
150.064 longitudinal bracket assembly 60. FS 132.900 Longitudinal Control Rod
(16) to FS 144.775 longitudinal bracket Assembly
assembly (24).
(Ref. Figure 410)
(6). Remove lower closet directional A. Longitudinal Control Rod Assembly
bellcrank assembly (Ref. Section Removal
67-20-00).
(1). Remove cyclic stick base assembly.
(7). Remove FS 150.164 lateral controls
bracket assembly. (2). Remove longitudinal control rod
assembly (Ref. Cyclic Stick Base
(8). Remove and discard cotter pin (1). Disassemble).
Remove bolt (27), washers (14 and 28)
B. Longitudinal Control Rod Assembly
and nut (26) that attach FS 144.775
Installation
longitudinal bellcrank assembly (29) to
FS 144.775 longitudinal bracket (1). Install longitudinal control rod assem
assembly (24). bly (Ref. Cyclic Stick Base Reassemble).
Page 444
(2). Install cyclic stick base assembly. (6). Install pilot crew seat (Ref. Section
25-10-00).
(3). Verify longitudinal cyclic control
rigging. 62. Longitudinal Closet Control Rod
Assembly
61. Longitudinal AftCockpit Control Rod
Assembly (Ref. Figure 410)
A. Longitudinal Closet Control Rod
(Ref. Figure 410)
Assembly Removal
A. Longitudinal AftCockpit Control Rod (1). Remove pilot crew seat (Ref. Section
Assembly Removal 25-10-00).
(1). Remove pilot crew seat (Ref. Section (2). Remove access panel AR138 (Ref.
25-10-00). Section 06-00-00).
(2). Remove access panel AR138 (Ref. (3). Remove insulation and controls closet
Section 06-00-00). panels behind right crew seat (Ref.
Section 25-10-00).
panels behind right crew seat (Ref. (4). Remove and discard cotter pin (1).
Section 25-10-00). Remove nut (2), washers (3), bolt (32),
grommet (33), spacer (34) and balance
(4). Remove and discard cotter pins (1). spring clip (46) that attach lower end of
Remove nut (2), washers (3) and bolt longitudinal closet control rod assembly
(25) that attach forward end of longitu (35) to FS 150.064 longitudinal bell
dinal aft cockpit control rod assembly crank assembly (10).
(15) to FS 144.775 longitudinal bell
crank assembly (29). (5). Remove and discard cotter pin (1).
(5). Remove and discard cotter pins (1). (36) that attach upper end of control
Remove nut (2), washers (3) and bolt (9) rod (35) to FS 157.387 longitudinal
that attach aft end of control rod (15) to bellcrank assembly (37).
FS 150.064 longitudinal bellcrank
assembly (10). B. Longitudinal Closet Control Rod
B. Longitudinal AftCockpit Control Rod (1). Install bolt, washers, and nut attaching
Assembly Installation upper end of longitudinal closet control
(1). Install bolt, washers, and nut attaching rod assembly to FS 157.387 longitudi
forward end of longitudinal aft cockpit nal bellcrank assembly. Torque nut and
control rod to FS 144.775 longitudinal install new cotter pin.
bellcrank assembly. Torque nut and (2). Install bolt, washers, nut, grommet,
install new cotter pin. spacer, and balance spring clip attach
ing lower end of control rod to FS
150.064 longitudinal bellcrank assem
aft end of control rod to FS150.064
bly. Torque nut and install new cotter
longitudinal bellcrank assembly. Torque
pin.
(3). Verify longitudinal cyclic control system
(3). Verify longitudinal cyclic rigging. rigging.
(4). Install controls closet and insulation (4). Install controls closet and insulation
Section 25-10-00). Section 25-10-00).
(5). Install access panel AR138 (Ref. (5). Install access panel AR138 (Ref.
Section 06-00-00). Section 06-00-00).
Page 445
(6). Install pilot crew seats (Ref. Section 64. Balance Spring Clip
25-10-00).
(Ref. Figure 410)
63. Extension Spring
A. Balance Spring Clip Removal
(Ref. Figure 410) (1). Remove pilot crew seat (Ref. Section
A. Extension Spring Removal 25-10-00).
(1). Remove pilot crew seat (Ref. Section (2). Remove access panel AR138 (Ref.
25-10-00). Section 06-00-00.
(2). Remove access panel AR138 (Ref. (3). Remove insulation and controls closet
Section 06-00-00). panels behind right crew seat (Ref.
Section 25-10-00).
panels behind right crew seat (Ref. (4). Remove and discard cotter pin (1).
Section 25-10-00). Remove nut (17), washers (18, 19 and
45), spacer (20), and bolt (21) that
(4). Remove and discard cotter pin (1). attach lower end of balance spring clip
Remove nut (17), washers (18, 19 and (46) to FS 150.064 longitudinal bell
45), spacer (20) and bolt (21) that crank assembly (10).
attach balance spring cable assembly
(22) to FS 150.064 longitudinal bell (5). Remove and discard cotter pin (1).
crank assembly (10). Remove nut (2), washers (3), bolt (32),
grommet (33) and spacer (34) that
(5). Remove and discard cotter pin (1). attach upper end of spring clip (46) to
Remove nut (38), washers (39, 40 and FS 150.064 longitudinal bellcrank
43), spacer (41) and bolt (44) that assembly (10).
attach lower end of extension spring
(42). B. Balance Spring Clip Installation
(1). Install bolt, washers, nut, grommet,
B. Extension Spring Installation
and spacer attaching upper end of
(1). Install bolt, spacer, washers, and nut balance spring clip to FS 150.064
attaching lower end of extension spring. longitudinal bellcrank assembly. Torque
(2). Install bolt, spacer, washers, and nut
attaching balance spring cable assem (2). Install bolt, spacer, washers, and nut
bly to FS 150.064 longitudinal bell attaching lower end of balance spring
crank assembly. clip to FS 150.064 longitudinal bell
crank assembly. Torque nut and install
(3). Torque nuts and install new cotter pins. new cotter pin.
(4). Install controls closet and insulation (3). Install controls closet and insulation
Section 25-10-00). Section 25-10-00).
(5). Install access panel AR138 (Ref. (4). Install access panel AR138 (Ref.
Section 06-00-00. Section 06-00-00).
(6). Install pilot crew seats (Ref. Section (5). Install pilot crew seats (Ref. Section
25-10-00). 25-10-00).
Page 446
65. Longitudinal Interconnect Control Rod (49) that attach interconnect control
Assembly rod assembly (53) and copilots FS
132.900 longitudinal control rod
(Ref. Figure 410) assembly (31) to FS 143.785 longitudi
nal bellcrank assembly (54).
A. Longitudinal Interconnect Control Rod
Assembly Removal (4). Remove and discard cotter pin (1).
(1). Remove both pilot and copilot crew Remove nut (2), washers (3) and bolt
seats (Ref. Section 25-10-00). (50) that attach bellcrank assembly (54)
to FS 143.785 longitudinal bracket
(2). Remove access panels AR138 and assembly (55).
AL138 (Ref. Section 06-00-00).
B. Longitudinal Bellcrank Assembly
(3). Remove and discard cotter pins (1). Installation
Remove nuts (2), washers (3) and bolts
(25 and 49) that attach both ends of (1). Install bolt, washers, and nut attaching
longitudinal interconnect control rod FS 143.785 longitudinal bellcrank
assembly (53). assembly to FS 143.785 longitudinal
bracket assembly.
NOTE: Removal of FS 144.775 longitudinal
bellcrank (29) or interconnect control rod as (2). Install bolts, washers, and nuts
sembly (53) rod end may be necessary to re attaching FS 132.900 longitudinal
move control rod assembly (53). control rod assembly and interconnect
control rod assembly to bellcrank.
B. Longitudinal Interconnect Control Rod Torque nuts and install new cotter pins.
(3). Install access panel AL138 (Ref. Section
(1). Install bolts, washers, and nuts 06-00-00).
attaching both ends of longitudinal
interconnect control rod assembly. (4). Install copilot crew seat (Ref. Section
Torque nut and install new cotter pin. 25-10-00).
(2). Verify longitudinal cyclic control system
rigging. 67. FS 143.785 Longitudinal Bracket
Assembly
(3). Install access panels AR138 and AL138
(4). Install both pilot and copilot crew seats A. Longitudinal Bracket Assembly Removal
66. FS 143.785 Longitudinal Bellcrank bellcrank assembly (54).
Assembly
(Ref. Figure 410) (3) that attach FS 143.785 longitudinal
bracket assembly (55) to airframe.
Removal
B. Longitudinal Bracket Assembly
(1). Remove copilot crew seat (Ref. Section Installation
25-10-00).
(1). Install bolts and washers attaching FS
(2). Remove access panel AL138 (Ref. 143.785 longitudinal bracket assembly.
Section 06-00-00). Torque bolts.
(3). Remove and discard cotter pins (1). (2). Install FS 143.785 longitudinal bell
Remove nuts (2), washers (3) and bolts crank assembly.
Page 447
VIEW ROTATED 1
37
23 3 2
3 6
24 3
16
1 3
2
14 36
REF. 35
33 34
REF. 35
3 32 3
3
14 46 1
9 REF. 10
47 35
REF. 5 REF. 10 9 2
14 15 3
4 3 12 (NOTE 1)
7 24 10
6
31 29
1 5 1 1
3 14
2 2
3
48 2 REF. 8 9
3 3
11 REF. 5
(NOTE 1)
13 56
(4 PL) 6
REF. 24 4 3
8
27
REF. 35 25
REF. 46 14
3
22 15
25
19 20
18
1 28
21 3
25
1 REF. 29 3 (2 PL)
17 2
2 REF. 31 1
3 30
VIEW ROTATED
45
TO DUAL
3 14 CONTROLS
3
3
1 26
REF. 10 41 40 30 2
43 39 2 (NOTE 2)
1
1
27 1
38
44 42
NOTES:
1. TORQUE 50 - 70 in-lb (5.64 - 7.90 Nm)
2. TORQUE 70 - 90 in-lb (7.90 - 10.16 Nm) 9G67-025-1B
Figure 410. Cockpit Longitudinal Cyclic Controls (Sheet 1 of 2)
Page 448
53
50
3 49 (2 PL)
51
3
3 (2 PL)
52
3
55
54
3 (2 PL)
3
31 (COPILOTS)
2 (2 PL) 1 (2 PL)
2
1 9G67-025-2
1. COTTER PIN 30. CYCLIC STICK LONGITUDINAL SECONDARY STOP

2. NUT 31. FS 132.900 LONGITUDINAL CONTROL ROD
3. WASHER ASSEMBLY
4. BOLT 32. BOLT
5. LONGITUDINAL GRADIENT SPRING 33. GROMMET
6. NUT 34. SPACER
7. LONGITUDINAL TRIM ACTUATOR CRANK ASSEMBLY 35. LONGITUDINAL CLOSET CONTROL ROD ASSEMBLY
8. LONGITUDINAL TRIM ACTUATOR 36. BOLT
9. BOLT 37. FS 157.387 LONGITUDINAL BELLCRANK ASSEMBLY
10. FS 150.064 LONGITUDINAL BELLCRANK ASSEMBLY 38. NUT
11. BOLT 39. WASHER
12. BOLT
40. WASHER
13. WASHER
41. SPACER
14. WASHER
42. EXTENSION SPRING
15. LONGITUDINAL AFT COCKPIT CONTROL ROD
43. WASHER
ASSEMBLY
44. BOLT
16. FS 150.064 LONGITUDINAL BRACKET ASSEMBLY
45. WASHER
17. NUT
46. BALANCE SPRING CLIP
18. WASHER
19. WASHER 47. BOLT
20. SPACER 48. BOLT
21. BOLT 49. BOLT
22. BALANCE SPRING CABLE ASSEMBLY 50. BOLT
23. BOLT 51. BOLT
24. FS 144.775 LONGITUDINAL BRACKET ASSEMBLY 52. BOLT
25. BOLT 53. LONGITUDINAL INTERCONNECT CONTROL ROD
26. NUT ASSEMBLY
27. BOLT 54. FS 143.785 LONGITUDINAL BELLCRANK ASSEMBLY
28. WASHER 55. FS 143.785 LONGITUDINAL BRACKET ASSEMBLY
29. FS 144.775 LONGITUDINAL BELLCRANK ASSEMBLY 56. WASHER
Figure 410. Cockpit Longitudinal Cyclic Controls (Sheet 2 of 2)
Page 449
68. FS 157.387 Longitudinal Bellcrank (5). Install FS 155.50 FOD cover (1)
Assembly (Ref. Section 67-10-00).
(Ref. Figure 411) (6). Install roof panels (Ref. Section

25-20-00).
Removal (7). Install controls closet panels behind
right crew seat (Ref. Section 25-10-00).
(1). Open access panels R155 and R210
(8). Install insulation panels behind right
crew seat (Ref. Section 25-10-00).
(2). Remove insulation panels behind right (9). Close access panels R155 and R210
crew seat (Ref. Section 25-10-00). (Ref. Section 06-00-00).
(3). Remove controls closet panels behind 69. FS 157.387 Longitudinal Control Rod
right crew seat (Ref. Section 25-10-00). Assembly
(4). Remove roof panels (Ref. Section (Ref. Figure 411)
25-20-00).
A. Longitudinal Control Rod Assembly
(5). Remove FS 155.50 FOD cover (1) Removal
(6). Remove and discard cotter pins (2). 25-20-00).
Remove nuts (3) washers (4) and bolts
(5) that attach longitudinal closet
Remove nut (3), washers (4) and bolt (5)
control rod assembly (6) and FS
that attach FS 157.387 longitudinal
157.387 longitudinal control rod
assembly (7) to FS 157.387 longitudinal
longitudinal bellcrank assembly (8).
bellcrank assembly (8).
Remove nut (3), washers (4) and bolt (9) (11) that attach control rod (7) to FS
that attach bellcrank assembly (8) to 171.090 longitudinal bellcrank assem
FS 155.50 control deck bracket assem bly (13).
bly (10).
(4). Remove control rod (7).
B. Longitudinal Control Rod Assembly
B. Longitudinal Bellcrank Assembly Installation
Installation
NOTE: Adjustment of control rods might be re
(1). Install bolt (9), washers (4) and nut (3) quired for installation.
attaching FS 157.387 longitudinal
(1). Install bolt (5), washers (4), and nut (3)
bellcrank assembly (8) to FS 155.50
attaching FS 157.387 longitudinal
control deck bracket assembly (10).
(2). Install bolts (5), washers (4), and nuts longitudinal bellcrank assembly (8).
(3) attaching longitudinal closet control (2). Install bolt (11), washers (4), and nut
rod assembly (6) and FS 157.387 (3) attaching control rod assembly (7) to
longitudinal control rod assembly (7) to FS 171.090 longitudinal bellcrank
bellcrank assembly (8). assembly (13).
(3). Verify longitudinal cyclic control system (3). Verify longitudinal cyclic control system
rigging (Ref. Section 67-10-00). rigging (Ref. Section 67-10-00).
(4). Torque nuts and install new cotter pins. (4). Torque nuts and install new cotter pins.
Page 450
(5). Install roof panels (Ref. Section (7). Close access panels R155 and R210
25-20-00). (Ref. Section 06-00-00).
70. FS 171.090 Longitudinal Bellcrank
Assembly 71. FS 171.090 Longitudinal Bracket
Assembly
(Ref. Figure 411)
A. Longitudinal Bellcrank Assembly (Ref. Figure 411)
Removal
(1). Open access panels R155 and R210 A. Longitudinal Bracket Assembly Removal
(1). Open access panels R155 and R210
(2). Remove roof panels (Ref. Section (Ref. Section 06-00-00).
25-20-00).
(3). Remove collective/longitudinal FOD (2). Remove roof panels (Ref. Section
cover (14) (Ref. Section 67-10-00). 25-20-00).
Remove nuts (3), washers (4) and bolts (3). Remove collective/longitudinal FOD
(11) that attach FS 157.387 longitudi cover (14) (Ref. Section 67-10-00).
nal control rod assembly (7) and
longitudinal to actuator control rod (4). Remove FS 171.090 longitudinal
assembly (15) to FS 171.090 longitudi bellcrank assembly (13) (Ref. Section
nal bellcrank assembly (13). 67-10-00).
Remove nut (3), washers (4) and bolt (5). Remove bolts (18), washers (17) that
(12) that attach bellcrank assembly (13) attach FS 171.090 longitudinal bracket
to FS 171.090 longitudinal bracket assembly (16) to mounting surface.
assembly (16).
(6). Remove bracket assembly (16).
B. Longitudinal Bellcrank Assembly B. Longitudinal Bracket Assembly
Installation Installation
(1). Install bolt (12), washers (4) and nut (3)
attaching FS 171.090 longitudinal (1). Install bolts (18), washers (17) attach
bellcrank assembly (13) to FS 171.090 ing FS 171.090 longitudinal bracket
longitudinal bracket assembly (16). assembly (16) to mounting surface.
Torque bolts.
(3) attaching FS 157.387 longitudinal
control rod assembly (7) and longitudi (2). Install FS 171.090 longitudinal bell
nal to actuator control rod assembly crank assembly (13) (Ref. Section
(15) to bellcrank assembly (13). 67-10-00).
(3). Verify longitudinal cyclic control system (3). Install collective/longitudinal FOD
rigging (Ref. Section 67-10-00). cover (14) (Ref. Section 67-10-00).
(5). Install collective/longitudinal FOD 25-20-00).
(6). Install roof panels (Ref. Section (5). Close access panels R155 and R210
25-20-00). (Ref. Section 06-00-00).
Page 451
72. Longitudinal To Actuator Control Rod B. Longitudinal To Actuator Control Rod

Assembly Assembly Installation
NOTE: Adjustment of control rod might be re
(Ref. Figure 411)
quired for installation.
A. Longitudinal To Actuator Control Rod (1). Install bolt, washers, and nut attaching
Assembly Removal longitudinal to actuator control rod
assembly to FS 171.090 longitudinal
(1). Open access panels R155 and R210 bellcrank assembly (13).
(Ref. Section 06-00-00). (2). Install collective/longitudinal FOD
cover (Ref. Section 67-10-00).
Remove nut (3), washers (4) and bolt Care should be taken to align
(19) that attach longitudinal to actua
CAUTION actuator bearing with mating
tor control rod assembly (15) to longitu clevis of control rod to prevent damage to
dinal servoactuator hydraulic unit (20). bearing seal during control rod attachment.
(3). Remove collective/longitudinal FOD attaching control rod assembly (15) to
cover (14) (Ref. Section 67-10-00). longitudinal servoactuator hydraulic
unit (20).
Remove nut (3), washers (4) and bolt (4). Verify longitudinal cyclic control system
(11) that attach control rod assembly rigging (Ref. Section 67-10-00).
(15) to FS 171.090 longitudinal bell
crank assembly (13).
(6). Close access panels R155 and R210
(5). Remove control rod assembly (15). (Ref. Section 06-00-00).
Page 452
20
15
14
1
10
13 REF. 15
8
16
4
7 3 4
19
2
6
REF. 20
REF. 13
2
3
REF. 8
4
11
2 4
3 2
REF. 7 4
4 4 REF. 15
5 3 3 18
4 4
2 2
REF. 6 REF. 16
3 4 11 17
4 2
4 5
3
9
12
REF. 10
4
REF. 7 9G67-026A
1. FS 155.50 FOD COVER 11. BOLT

3. NUT 13. FS 171.090 LONGITUDINAL BELLCRANK ASSEMBLY
4. WASHER 14. COLLECTIVE/LONGITUDINAL FOD COVER
5. BOLT 15. LONGITUDINAL TO ACTUATOR CONTROL ROD
6. LONGITUDINAL CLOSET CONTROL ROD ASSEMBLY ASSEMBLY
7. FS 157.387 LONGITUDINAL CONTROL ROD 16. FS 171.090 LONGITUDINAL BRACKET ASSEMBLY
ASSEMBLY 17. WASHER
8. FS 157.387 LONGITUDINAL BELLCRANK ASSEMBLY 18. BOLT
9. BOLT 19. BOLT
10. FS 155.50 CONTROL DECK BRACKET ASSEMBLY 20. SERVOACTUATOR HYDRAULIC UNIT
Figure 411. Upper Deck Longitudinal Cyclic Controls
Page 453
73. Control Deck Bracket Assembly 74. FS 155.500 FOD Cover
A. Control Deck Bracket Assembly Removal Consumable Materials

(Ref. CSPSPM)
(1). Remove FS 155.500 FOD cover (1) Item Nomenclature
(Ref. Section 67-10-00). C235 Release Agent, Fluorocarbon
(2). Remove FS 157.590 directional bell
crank assembly (Ref. Section
67-20-00). A. FOD Cover Removal
(3). Remove FS 157.387 longitudinal (1). Open access panel R155 (Ref. Section
bellcrank assembly (Ref. Section 06-00-00).
67-10-00). (2). Remove screws (5) and washers (6) that
attach FS 155.500 FOD cover (1) to
(4). Remove FS 157.730 collective bellcrank mounting surfaces.
NOTE: Sealing compound used between FOD
(5). Remove upper closet lateral bellcrank cover and mounting surface is actually a
assembly (Ref. Section 67-10-00). self-forming gasket. Care should be taken
not to damage this gasket when removing
(6). Remove bolts (2) and washers (3) that FOD cover.
attach control deck bracket assembly
(4) to mounting deck surface. (3). Using a putty knife (or equivalent), if
(7). Remove bracket assembly (4). faying surfaces of FOD cover (1) and
mounting surfaces.
B. Control Deck Bracket Assembly (4). Remove FOD cover (1).
Installation
B. FOD Cover Installation
NOTE: Use washers (3) as required to compen
sate for variance in sealant thickness NOTE: Proceed with the following steps, only if
around FOD covers. forming a new FOD cover seal.
Release Agent, Fluorocarbon (C235)
attaching control deck bracket assem
bly (4) to deck. Torque bolts.
(2). Install upper closet lateral bellcrank

(1). Apply mold fluorocarbon release agent
(C235) to FOD cover (1) faying surface
only.
(3). Install FS 157.730 collective bellcrank
assembly (Ref. Section 67-10-00). Sealing Compound (C205)
(4). Install FS 157.387 longitudinal bell

crank assembly (Ref. Section
67-10-00).
(5). Install FS 157.590 directional bellcrank faying surface of FOD cover.
(3). Press FOD cover down on faying deck
(6). Install FS 155.500 FOD cover (1) (Ref. surface with enough pressure to cause
Section 67-10-00). squeeze out of compound.
Page 454
NOTE: Screws are only to keep holes from clog NOTE: Sealing compound used between FOD
ging. cover and mounting surface is actually a
self-forming gasket. Care should be taken
(4). Install screws but do not tighten down. not to damage this gasket when removing
FOD cover.
(5). FOD cover may be removed leaving
formed seal to remain on deck surface (6). Using a putty knife, if necessary,
to cure, or leave cover in place and carefully break seal between faying
continue work. Allow compound to cure surfaces.
for 12 hours.
(7). Remove FOD cover (9).
NOTE: Proceed with the following steps if the
original FOD cover seal is not damaged. (8). Remove upper deck control rod boots
(10) (Ref. Section 67-10-00).
(6). Apply sealant (C205) to screws attach
ing vertical mounting surface of FOD B. FOD Cover Collective/Longitudinal
cover. Installation
(7). Install screws and washers attaching (1). Install upper deck control rod boots (10)
FOD cover to mounting surfaces . onto FOD cover (Ref. Section
Torque screws. 67-10-00).
(8). Close access panel R155 (Ref. Section Release Agent, Fluorocarbon (C235)
06-00-00).
75. FOD Cover Collective/Longitudinal

(Ref. Figure 412) NOTE: Proceed with the following steps, only if
forming a new FOD cover seal.
Consumable Materials (2). Apply mold fluorocarbon release agent
(Ref. CSPSPM) (C235) to collective/longitudinal FOD
Item Nomenclature cover faying surface only.
A. FOD Cover Collective/Longitudinal

Removal
(1). Remove access panels R155, T155 and faying surface of FOD cover (9).
L155 (Ref. Section 53-30-00).
(4). Press FOD cover (9) down on faying
(2). Remove dual hydraulic actuator units deck surface with enough pressure to
(24 and 25) (Ref. Section 67-10-00). cause squeeze out of compound.
(3). Loosen hose clamps (23) on upper deck NOTE: Bolts are only to keep holes from clog
collective and longitudinal control rod ging.
boots (10).
(5). Install bolts (7) but do not tighten
(4). Remove bolts (7) and washers (8) that down.
attach collective/longitudinal FOD
cover (9) to the mounting deck surface. (6). FOD cover (9) may be removed leaving
formed seal to remain on deck surface
(5). Remove screws (35) and washers (36) to cure, or leave cover (9) in place and
that attach drip pan drains (33) to drip continue work. Allow compound to cure
pan (31). for 12 hours.
Page 455
NOTE: Proceed with the following steps if the NOTE: Sealing compound used between FOD
original FOD cover seal is not damaged. cover and mounting surface is actually a
self-forming gasket. Care should be taken
(7). Install bolts (7) and washers (8) not to damage this gasket when removing
attaching FOD cover (9) to deck. FOD cover.
(8). Torque bolts. (6). Using a putty knife, (or equivalent) if
(9). Install screws (35) and washers (36) faying surfaces.
attaching drip pan drain (33) to drip
pan (31). (7). Remove FOD cover (11).
(10). Install dual hydraulic actuator units (8). Remove lateral upper deck control rod
(24 and 25) (Ref. Section 67-10-00). boot (14) (Ref. Section 67-10-00).
(11). Tighten hose clamps (23) on upper deck B. Lateral FOD Cover Installation
collective and longitudinal control rod
boots (10). (1). Install lateral upper deck control rod
boot (14) onto lateral FOD cover (11)
(12). Verify collective and longitudinal cyclic (Ref. Section 67-10-00).
rigging (Ref. Section 67-10-00).
(14). Install access panels R155, T155 and

L155 (Ref. Section 53-30-00).
NOTE: Proceed with the following steps, only if
76. Lateral FOD Cover forming a new FOD cover seal
(Ref. Figure 412) (2). Apply mold fluorocarbon release agent

(C235) to lateral FOD cover (11) faying
surface only.
(Ref. CSPSPM) Sealing Compound (C205)
Item Nomenclature
C235 Release Agent, Fluorocarbon

A. Lateral FOD Cover Removal faying surface of FOD cover (9).
(1). Remove access panels R155, T155 and (4). Press FOD cover (11) down on faying
L155 (Ref. Section 53-30-00). deck surface with enough pressure to
cause squeeze out of compound.
(2). Remove lateral dual hydraulic actuator
unit (26) (Ref. Section 67-10-00). NOTE: Screws are only to keep holes from clog
ging.
(3). Loosen hose clamp (23).
(5). Install screws (5) but do not tighten
(4). Remove screws (5), washers (6) that down.
attach lateral FOD cover (11) to
mounting deck surface. (6). FOD cover (11) may be removed leaving
formed seal to remain on deck surface
(5). Remove screws (35) and washers (36) to cure, or leave cover (11) in place and
that attach drip pan drain (33) to drip continue work. Allow compound to cure
pan (32). for 12 hours.
Page 456
NOTE: Proceed with the following steps if the (Ref. Section 67-10-00) with drip pans
original FOD cover seal is not damaged. (31 and 32).
(7). Install screws (5) and washers (6) (5). Remove upper deck control rod boots
attaching FOD cover (11) to mounting (10 or 14) (Ref. Section 67-10-00).
surface.
(6). Separate bond between FOD covers (9
(8). Install screws (35) and washers (36) and 11) and drip pans (31 and 32) and
attaching drip pan drain (33) to drip remove.
pan (32).
B. Drip Pan Assembly Installation
(9). Install lateral dual hydraulic actuator Sealing Compound (C205)
unit (26) (Ref. Section 67-10-00).
(10). Tighten hose clamp (23) on lateral

upper deck control rod boot (14).
(11). Verify lateral cyclic rigging (Ref. Section (1). Bond drip pan assemblies (31 and 32)
67-10-00). to FOD covers (9 and 11) using sealing
compound (C205).
(2). Install upper deck control rod boots (10
(13). Tighten hose clamp (23). or 14) (Ref. Section 67-10-00).
(14). Install access panels R155, T155 and (3). Install collective/longitudinal FOD
L155 (Ref. Section 53-30-00). cover (9) and lateral FOD cover (11)
(Ref. Section 67-10-00) with drip pans
77. Drip Pan Assembly, RH and LH (31 and 32).
(Ref. Figure 412) (4). Install screws (35) and washers (36)
attaching drip pan drains (33) to drip
pans (31 and 32).
(Ref. CSPSPM) (5). Install hydraulic actuator units (24, 25
Item Nomenclature and 26) (Ref. Section 67-10-00).
C205 Sealing Compound (6). Install access panels R155, T155 and
L155 (Ref. Section 53-30-00).
A. Drip Pan Assembly Removal 78. Control Rod Boot, Upper Deck
NOTE: Drip pan clip assembly (37) on RH Drip (Ref. Figure 412)
Pan Assembly is attached with screws (35)
and washers (36), clip assembly on LH Drip
Pan is riveted to pan. Consumable Materials
(Ref. CSPSPM)
(1). Remove access panels R155, T155 and Item Nomenclature
L155 (Ref. Section 53-30-00). C205 Sealing Compound
C235 Release Agent, Fluorocarbon
(2). Remove dual hydraulic actuator units
(24, 25 and 26) (Ref. Section 67-10-00).
A. Control Rod Boot Removal
that attach drip pan drains (33) to drip NOTE: This task is typical for all three upper
pans (31 and 32). deck control rod boots.
(4). Remove collective/longitudinal FOD (1). Remove access panels R155, T155 and
cover (9) and lateral FOD cover (11) L155 (Ref. Section 53-30-00).
Page 457
NOTE: Old configuration lateral FOD cover (3). Press boot (10 or 14) down on faying
(11) uses screws (5), washers (12) and nuts FOD cover surface with enough
(13) to attach control rod boot (14). FOD cov pressure to cause squeeze out of
er (11) will need to be removed to separate compound.
boot (14) from cover (11). New configuration
cover (11) utilizes nutplates on the under NOTE: Screws are only to keep holes from clog
side of FOD cover. ging.
Remove nuts (18), washers (17) and (4). Install screws (5) but do not tighten
bolts (16) that attach upper end of down.
actuator control rods to hydraulic
actuator units (24, 25 and 26).
(5). Remove boot leaving formed seal to
(3). Loosen hose clamps (23). remain on FOD cover surface to cure.
Allow compound to cure for 12 hours.
that attach boots (10 or 14) to FOD NOTE: Proceed with the following steps if the
covers (9 or 11). original FOD cover seal is not damaged.
(5). Using a putty knife, (or equivalent) if
necessary, carefully break seal between Sealing Compound (C205)
faying surfaces.
(6). Remove boots (10 or 14).
B. Control Rod Boot Installation
(Ref. Figure 412) (6). Apply sealing compound (C205) to
screws (5).
NOTE:
This task is typical for all three upper NOTE: Old configuration lateral FOD cover
deck control rod boots. (11) uses screws (5), washers (12) and nuts
If the original seal is not damaged, start (13) to attach control rod boot (14). New con
with step (6). figuration utilizes nutplates on the under
side of FOD cover.
attaching boots (10 or 14) to FOD cover.
(8). Torque screws (5).

(1). Apply mold fluorocarbon release agent
(C235) to control rod boots (10 or 14)
faying surface only. (9). Tighten hose clamps (23).
NOTE: Proceed with the following steps, only if (10). Install bolts (16), washers (17) and nuts
forming a new FOD cover seal. (18) attaching upper end of actuator
Sealing Compound (C205) control rods to hydraulic actuator units
(24, 25 and 26).
(2). Apply sealing compound (C205) to (12). Install access panels R155, T155 and
faying surface of boot (10 or 14). L155 (Ref. Section 53-30-00).
Page 458
79. Tailstock Boot, Upper Deck (6). Remove and discard cotter pins (30).
Remove nuts (29), washers (28) and
(Ref. Figure 412 bolts (27) that attach both ends of dual
hydraulic actuator units (24, 25 and 26)
A. Tailstock Boot Removal to mixer assembly (19) and boosted
system bracket assembly (20).
(1). Remove access panels R155, T155 and
L155 (Ref. Section 53-30-00).
(7). Remove actuator unit (24, 25 and 26).
(24, 25 and 26) (Ref. Section 67-10-00).
B. Dual Hydraulic Actuator Unit Installation
(3). Remove upper deck tailstock boots (34).
B. Tailstock Boot Installation NOTE: This task is typical for all three actua
tor units.
(1). Install upper deck tailstock boots (34)
onto boosted system bracket assembly
(20) and drip pans (31 and 32).
(29) attaching both ends of dual
(2). Install dual hydraulic actuator units hydraulic actuator units (24, 25 and 26)
(24, 25 and 26) (Ref. Section 67-10-00). to mixer assembly (19) and boosted
system bracket assembly (20).
L155 (Ref. Section 53-30-00). (2). Attach lateral to actuator, longitudinal
to actuator and collective to actuator
80. Dual Hydraulic Actuator Unit, Rotor control rods (Ref. Section 67-10-00).
Control
(Ref. Figure 412) (3). Verify collective and cyclic rigging (Ref.
Section 67-10-00).
(Ref. CSPSPM) (4). Torque all nuts and install new cotter
Item Nomenclature pins.
C702 Lockwire
(5). Attach hydraulic lines to actuators (Ref.
A. Dual Hydraulic Actuator Unit Removal Section 29-00-00).
NOTE: This task is typical for all three actua (6). Safety hydraulic line connections using
tor units. lockwire (C702).
(1). Remove access panels R155, T155 and
L155 (Ref. Section 53-30-00). (7). Restore pressure to hydraulic system
(2). Remove pressure from hydraulic
system (Ref. Section 29-00-00).
Verify no leaks are present in
(3). Remove and discard lockwire from CAUTION flammable fluid systems, where
hydraulic line connections. maintenance or replacement of components,
lines, or fittings has occurred, by application
(4). Disconnect hydraulic lines from of system pressure and visual inspection
actuators (Ref. Section 29-00-00). prior to helicopter being returned to service.
(5). Detach lateral to actuator, longitudinal
to actuator and collective to actuator (8). Install access panels R155, T155 and
control rods (Ref. Section 67-10-00). L155 (Ref. Section 53-30-00).
Page 459
81. Boosted System Bracket Assembly B. Boosted System Bracket Assembly

Installation
(Ref. Figure 412)
A. Boosted System Bracket Assembly (1). Install bolts (21and 22) and washers
Removal (17) attaching boosted system bracket
(1). Remove access panels R155, T155 and assembly (20) to mounting deck
L155 (Ref. Section 53-30-00). surface. Torque bolts.

(24, 25 and 26) (Ref. Section 67-10-00). (2). Install collective/longitudinal fod cover
(9) and lateral fod cover (11) (Ref.
(3). Remove collective/longitudinal fod cover Section 67-10-00) with drip pans (31
(9) and lateral fod cover (11) with drip and 32).
pans (31 and 32) (Ref. Section
67-10-00).
(3). Install dual hydraulic actuator units
(4). Remove bolts (21 and 22) and washers (24, 25 and 26) (Ref. Section 67-10-00).
(17) that attach bracket assembly (20)
to mounting deck surface.
(5). Remove bracket assembly (20). L155 (Ref. Section 53-30-00).
Page 460
24
25
26 19
1
6 23
(3 PL)
10
5
(NOTE 1) 9 14
20
11
REF. 10
4 5
(NOTE 2)
REF. 23
28 28 12
29
REF. 10
27 34
30
18 17 35 (4 PL)
15 17 36 (4 PL)
REF. 19
16 33 2 PL
37
6 PLACES 36 35
31
7
REF. 23
3 PLACES
8 REF. 9
5
32 (NOTE 2)
21 12
5 PL
17
REF. 14
22
2 PL
17 12
REF. 11
13
REF. 20
5 (NOTE 1)
6 OLD
CONFIGURATION
NOTES: 8 PL
1. TORQUE 20 -25 in-lb (2.25 - 2.82 Nm)
2. TORQUE 12 -15 in-lb (1.35 - 1.69 Nm)
9G67-008B
Figure 412. Upper Deck FOD Covers, Boots and Actuators
Page 461

1. FS 155.500 FOD COVER 20. BOOSTED SYSTEM BRACKET ASSEMBLY
2. BOLT 21. BOLT
3. WASHER 22. BOLT
4. CONTROL DECK BRACKET ASSEMBLY 23. HOSE CLAMP
5. SCREW 24. LONGITUDINAL HYDRAULIC ACTUATOR
6. WASHER 25. COLLECTIVE HYDRAULIC ACTUATOR
7. BOLT 26. LATERAL HYDRAULIC ACTUATOR
8. WASHER
27. BOLT
9. COLLECTIVE/LONGITUDINAL FOD COVER
28. WASHER
10. UPPER DECK CONTROL ROD BOOT
29. NUT
11. LATERAL FOD COVER
30. COTTER PIN
12. WASHER
13. NUT 31. DRIP PAN, RH
14. LATERAL UPPER DECK CONTROL ROD BOOT 32. DRIP PAN, LH
15. COTTER PIN 33. DRIP PAN DRAIN
16. BOLT 34. TAILSTOCK BOOT
18. NUT 36. WASHER
19. MIXER ASSEMBLY 37. CLIP ASSEMBLY, DRIP PAN
Page 462
ROTOR FLIGHT CONTROLS

INSPECTION/TEST/RIGGING PROCEDURE
1. Rotor Flight Control System
CAUTION
Do not move rotor flight controls through
A. Rotor Flight Control System Inspection their full range unless hydraulic power is
(Area 1) supplied to the helicopter.
Cyclic stick must be centered before you
move collective control through its full
Special Tools range of travel.
(Ref. CSPSPM)
Item Nomenclature
Collective control must be set at approxi
mately 80% before you move cyclic control
T2001 Hydraulic Mule through its full range of travel.
T2002 Ground Power Unit (5). Apply 1000 psig (6894.8 kPa) hydrau
number 1, use hydraulic mule (T2001)
(1). Examine cyclic and collective boots for
cracks, wear, and correct installation. (6). Apply external electrical power, use
No defects or incorrect installation ground power unit (T2002) (Ref.
permitted. CSP-900RMM-3).
(7). Make sure main rotor flight controls
operate smoothly, move easily, and
(2). Examine cyclic and collective sticks for
move freely. No defects permitted.
damage and corrosion. No damage or
corrosion permitted. (a). If main rotor flight controls do not
move freely and you think the
longitudinal and/or lateral gradient
(3). Copilot (Quick Release) Cyclic Stick springs are the possible cause,
Remove and examine copilot cyclic stick remove gradient springs and do the
expandable diameter bolts for cracks test that follows.
and corrosion. None permitted.
(b). If the torque necessary to turn one of
the two rod end balls around the axis
(a). Install expandable diameter bolts. of the bolt hole is more than 1.0 in-oz
Adjust diameter of bolt so force (7.06 mNwm), replace gradient spring.
necessary to engage cam handle is (8). Make sure longitudinal and lateral trim
11-14 lb (5-6.35 kg). Apply force at actuators function correctly. No incor
center of spring clip. rect function permitted.
(9). Examine main rotor flight controls for
(4). Copilot (Quick Release) Collective too much play. Too much play is not
Stick (902 CONFIG) Remove and permitted.
examine quick release pin for cracks
If collective position sensor link
and corrosion. None permitted. CAUTION and collective position sensor
bellcrank go past center or become aligned,
Moving Flight Controls the collective controls can become locked or
position sensor can send an incorrect signal
to the VSCS system.
(10). Pull pilot collective friction release
switch and move collective stick to full
Page 601
up position and make sure collective B. Rotor Flight Control System Inspection
position sensor link and collective (Area 2)
position sensor bellcrank do not go past Moving Flight Controls
center or become aligned.
(11). If necessary, adjust cockpit collective

control tube and collective closet
controls rod to rotate collective position CAUTION
sensor link and collective position
sensor bellcrank so they do not go past Do not move rotor flight controls through
center or become aligned. Do the their full range unless hydraulic power is
collective controls part of rotor flight supplied to the helicopter.
controls rigging verification. Cyclic stick must be centered before you
move collective control through its full
range of travel.
(12). Examine all linkage and components
(under crew station floor and in controls Collective control must be set at approxi
closet) for damage, corrosion, and that mately 80% before you move cyclic control
they move freely. No defects permitted. through its full range of travel.
(1). Apply 1000 psig (6894.8 kPa) hydrau
(13). Make sure all nuts and bolts are number 1, use hydraulic mule (T2001)
correctly installed and safety devices (Ref. Section 29-00-00).
are installed. If safety device is missing,
torque nut or bolt and install new (2). Apply external electrical power, use
safety device. ground power unit (T2002) (Ref.
CSP-900RMM-3).
(14). Examine all control rods and rod/clevis (3). Examine main rotor flight controls for
ends for damage and bearings for rough too much play. Too much play is not
operation or too much play. No damage permitted.
or too much play permitted. (4). Examine all linkage and components
(under upper deck) for damage, corro
(a). Maximum scratch limit for FS 153.5 sion, and that they move freely. No
collective closet control rod, are 2 in. defects permitted.
(5.08 cm) long by 0.005 in. (0.127 (5). Make sure all nuts and bolts are
mm) deep in the constant diameter correctly installed and safety devices
part of the rod. Scratches within are installed. If safety device is missing,
these limits must be polished out. torque nut or bolt and install new
Apply chemical coating and primer safety device.
after polish (Ref. CSP-SPM).
(6). Examine all control rods and rod/clevis
ends for damage and bearings for rough
(15). Examine bellcranks and brackets for operation or too much play. No damage
correct installation and damage. And or too much play permitted.
bearings and/or bushings for rough (7). Examine bellcranks and brackets for
operation or too much play. No defects correct installation and damage. And
permitted. bearings and/or bushings for rough
operation or too much play. No defects
(16). Remove hydraulic pressure (Ref. permitted.
Section 29-00-00). (8). Remove hydraulic pressure (Ref.
Section 29-00-00).
(17). Remove external electrical power (Ref. (9). Remove external electrical power (Ref.
CSP-900RMM-3). CSP-900RMM-3).
Page 602
C. Rotor Flight Control System Inspection (a). Measure and make a record of the
(Area 3) torque necessary to turn the servoac
tuator input bearing. Maximum
Moving Flight Controls torque permitted 8.7 in-lb (0.983
Nwm).
(b). Measure and make a record of the
axial play of the servoactuator input
bearings. Maximum axial play
permitted 0.025 in. (0.635 mm).
CAUTION
(8). Examine FOD covers for cracks,
Do not move rotor flight controls through separation from their attach surface,
their full range unless hydraulic power is and defects. No defects permitted.
supplied to the helicopter. (9). Examine bellcranks and brackets for
Cyclic stick must be centered before you correct installation and damage. And
move collective control through its full bearings and/or bushings for rough
range of travel. operation or too much play. No defects
permitted.
Collective control must be set at approxi
mately 80% before you move cyclic control (10). Remove hydraulic pressure (Ref.
through its full range of travel. Section 29-00-00).
(1). Apply 1000 psig (6894.8 kPa) hydrau (11). Remove external electrical power (Ref.
lic pressure to hydraulic system CSP-900RMM-3).
number 1, use hydraulic mule (T2001) D. Rotor Flight Control System Operational
(Ref. Section 29-00-00). Test

Special Tools
ground power unit (T2002) (Ref.
(Ref. CSPSPM)
CSP-900RMM-3).
Item Nomenclature
(3). Examine main rotor flight controls for T2001 Hydraulic Mule
too much play. Too much play is not T2002 Ground Power Unit
permitted.
(4). Make sure all nuts and bolts are
correctly installed and safety devices
are installed. If safety device is missing,
torque nut or bolt and install new
safety device.
CAUTION
(5). Examine all control rods and rod/clevis
ends for damage and bearings for rough Do not move rotor flight controls through
operation or too much play. No damage their full range unless hydraulic power is
or too much play permitted. supplied to the helicopter.
Cyclic stick must be centered before you
(6). Examine rotor servoactuators for move collective control through its full
cracks, corrosion, or other damage. range of travel.
Examine visible part of servoactuator Collective control must be set at approxi
shaft for scores, leakage, or corrosion. mately 80% before you move cyclic control
No defects permitted. through its full range of travel.
(7). Disconnect servoactuator input control (1). Apply 1000 psig (6894.8 kPa) hydrau
rods at the servoactuator input levers. lic pressure to hydraulic system
Page 603
number 1 with hydraulic mule (T2001) (15). Move cyclic stick forward until it
(ref. Section 29-00-00). touches forward stop. Release stick and
let it go back to the center position.
(2). Apply external electrical power with
ground power unit (T2002) (ref. (16). Move cyclic stick aft until it touches aft
CSP-900RMM-3). stop. Release stick and let it go back to
the center position.
(3). Pull collective friction release switch,
(17). Move cyclic stick right until it touches
raise collective stick to approximately
the right stop. Release stick and let it
80% as shown on the IIDS, and release
go back to the center position.
switch.
(18). Move cyclic stick left until it touches
(4). Move cyclic stick full forward, aft, left the left stop. Release stick and let it go
and right. Cyclic stick should move back to the center position.
freely through full range of travel.
(19). On helicopters with copilot controls
(5). Trim cyclic stick full forward. Pull stick installed, do steps (4). thru (18). with
full aft and make sure it goes back to copilot cyclic controls.
full forward when released.
(20). Make sure cyclic stick is centered after
(6). Trim cyclic stick aft until the trim cyclic part of test is complete (ref. Part
motor stops. Push stick full forward and E., Cyclic Stick in Center Position
make sure it goes back to full aft when Procedure).
released. (21). Pull pilot collective friction release switch
(5 lb [2.27 kg]) and move the collective
(7). Make sure the time to trim from aft stick from full down to full up and back
trim motor stop to forward trim motor to full down.
stop is 15 to 23 seconds.
(a). Measure the force at the base of the
(8). Make sure the time to trim from grip, near the attachment screw.
forward trim motor stop to aft trim
motor stop is 15 to 23 seconds. (b). The force necessary to move the stick
must be equal to the force to move
(9). With cyclic stick trimmed approximately the stick down within 1 lb (0.45 kg).
center, the force to move the stick (c). Make sure collective controls operate
forward and aft should be equal to
smoothly, move easily, and move
within 1 lb (0.45 kg).
freely.
(10). Trim cyclic stick full left, pull the stick (22). Set the collective release switch to the
right and make sure it goes back to full high force setting (25 lb [11.34 kg]).
left when released.
(a). Measure the force at the base of the
(11). Trim cyclic stick right until the trim grip, near the attachment screw.
motor stops. push the stick full left and
(b). Up force plus down force divided by
make sure it goes back to full right
two must be 30 to 40 lb (13.61 to
when released.
18.14 kg).
(12). Make sure the time to trim from right (23). Pull collective friction release switch
trim motor stop to left trim motor stop and move collective stick to middle
is 15 to 23 seconds. position and set Collective Friction Unit
(CFU). Stick should stay in position. Do
(13). Make sure the time to trim from left again at other stick positions to make
trim motor stop to right trim motor stop sure of full CFU operation.
is 15 to 23 seconds.
(24). Pull collective friction release switch,
(14). Set cyclic trim actuators to the center lower collective stick to down stop, and
position. release switch.
Page 604
(25). Remove hydraulic pressure (ref. Section (2). Apply external electrical power with
29-00-00). ground power unit (T2002) (ref.
CSP-900RMM-3).
(26). Remove external electrical power (ref.
CSP-900RMM-3). NOTE:
Cyclic stick must be in center position
E. Cyclic Stick In Center Position Procedure
both laterally and longitudinally.
(Ref. Figure 601) Do this procedure while sitting in the pi
lot crew seat.
Special Tools (3). Detach bottom of cyclic stick center
(Ref. CSPSPM) position strap (1).
Item Nomenclature
T2001 Hydraulic Mule (4). Extend cyclic stick center position strap
T2002 Ground Power Unit (1) forward until it touches instrument
panel (3) cyclic stick center position
placard (2).
NOTE: Do this procedure when the helicopter
is serviced, in maintenance, or shutdown. (5). Strap (1) must be fully extended, in line
with placard (2), and touch placard (2).
Moving Flight Controls If necessary, move cyclic stick (4).
(6). Attach bottom of cyclic stick center

position strap (1).
(7). Remove hydraulic pressure (ref. Section

(1). Apply 1000 psig (6894.8 kPa) hydrau 29-00-00).
number 1 with hydraulic mule (T2001) (8). Remove external electrical power (ref.
(ref. Section 29-00-00). CSP-900RMM-3).
REF. 3 REF. 1
(EXTENDED POSITION)
2
REF. 1 1 (STOWED POSITION)
(EXTENDED
POSITION)
REF. 4

(CYCLIC GRIP REMOVED FOR CLARITY) VIEW LOOKING INBOARD
FROM RIGHT SIDE 9G67-040A
1. CYCLIC STICK CENTER POSITION STRAP 3. MAIN INSTRUMENT PANEL

2. CYCLIC STICK CENTER POSITION PLACARD 4. CYCLIC STICK
Figure 601. Cyclic Stick In Center Position Procedure
Page 605
F. Rotor Servoactuator Functional Test (i). Torque wrench (dial type).

(Ref. Figure 602) (j). Hydraulic fluid, Mil-H-83232.
NOTE: All test equipment and interconnect
NOTE: This test procedure is to make sure the hoses must be number 4 port (0.25 in. (6.35
servoactuator functions correctly. It is not
mm) minimum.
an overhaul or repair procedure.
(3). Functional Test Procedure:
(1). Tests:
(a). Fully clean and dry external surface
(a). Attach bearings and input lever of servoactuator. Put caps on pres
bearing test. sure and return ports to prevent
contamination.
1). Makes sure radial movement of
bearing inner race is correct. (b). Install correct dimension bolt,
washers, and nut in servoactuator
2). Makes sure torque necessary to attach and in input lever bearings.
turn bearings is correct. Tighten sufficiently to prevent
movement of bolts in bearings.
(b). Make sure static and dynamic seal
are serviceable. (c). Measure torque necessary to turn
inner race of each bearing, use torque
(c). Make sure motion and stroke of wrench on bolt.
servoactuator piston is correct. 1). Maximum torque to turn servoac
(d). Make sure the force necessary on the tuator attach bearings 21.7 in-lb
input lever to cause servoactuator (2.45 Nwm).
movement is correct. 2). Maximum torque to turn input
lever bearing 1.4 in-lb (0.158
(e). Make sure piston moves at correct Nwm).
speed.
(d). Attach bottom attach point of servo
(2). Equipment: actuator to an applicable device to
prevent movement of servoactuator.
(a). Fluid container with approximately Make sure input lever and moveable
0.5 gallon (1.89 L) capacity. end of servoactuator can move freely.
(b). Hydraulic pressure source controlled (e). Connect pressure PRESS and return
at 2 gpm (7.57 lpm) @ @ 500 psig RTN test hoses to servoactuator.
(3447.5 kPa).
Maximum hydraulic pres
(c). Shut off valve applicable for 500 psig WARNING sure during this functional
(3447.5 kPa). test is 500 psig (3447.5 kPa).
(d). 5 micron filter applicable for 500 (f). Set shut off valve of test equipment
psig (3447.5 kPa). to ON position and apply hydraulic
pressure.
(e). 4 way valve applicable for 500 psig (g). Push input lever of servoactuator in
(3447.5 kPa). the extend direction until servoactua
tor is fully extended.
(f). Pressure gauge (0-500 psig
(0-3447.5 kPa). (h). Push on input lever of servoactuator
in the retract direction until servoac
(g). Check valve applicable for 500 psig tuator is fully retracted.
(3447.5 kPa) with 15 psid or less @
2.2 gpm (8.327 liters per minute)). (i). Extend and retract servoactuator
continuously until hoses and servoac
(h). Force measurement device, precision tuator are fully bled. Refill reservoir
of "0.1 lb (0.045 kg). as necessary.
Page 606
(j). Continue to operate servoactuator (o). Measure servoactuator range of

through its full range of travel in travel. Range of travel must be
both retract and extend directions. 2.00-2.04 in. (50.8-51.8 mm).
(k). Monitor the piston rod for smooth (p). Cycle servoactuator through its full
movement and no vibration in each range of travel in both retract and
of the two directions. extend directions. The pressure of the
test equipment must not go lower
(l). Visually examine seals for parts that
than the 500 psig (3447.5 kPa)
do not move for indication of leakage.
controlled pressure.
No leakage is permitted.
(m). Visually examine seals for parts that (q). Measure the time necessary for
move for indication of too much servoactuator to move from fully
leakage. Maximum leakage per retracted to fully extended (or from
mitted, one drop in 25 cycles (each fully extended to fully retracted).
seal). Maximum time permitted is 1
second. Usual time will be 0.70-0.85
(n). Measure force necessary on input seconds.
lever to cause movement of actuator,
use force measurement device. (r). If servoactuator does not extend or
Maximum force permitted 1 lb (0.454 retract as specified in steps (o). thru
kg). (q)., replace servoactuator.
HYDRAULIC PRESSURE SOURCE
FLUID
CONTAINER
FILTER
CHECK
VALVE
SHUT OFF
VALVE
PRESSURE
GAUGE
SERVOACTUATOR PRESSURE SERVOACTUATOR RETURN

CONNECTIONS CONNECTIONS
BOTTOM ATTACH END

MOVEABLE END
PRESS RET PRESS RET
INPUT LEVER
RETRACT EXTEND SERVOACTUATOR

9G67-038A
Figure 602. Rotor Servoactuator Functional Test Schematic
Page 607
G. Rotor Flight Controls Travel Check (5). Pull collective friction release switch
(12), lower collective stick (8) to down
(Ref. Figure 603) stop (13), and release switch.
(6). Make sure collective servoactuator
input lever (4) is overtraveled in the
Special Tools retracted direction.
(Ref. CSPSPM)
Item Nomenclature (7). Pull collective friction release switch
(12), raise collective stick (8) full up,
T2001 Hydraulic Mule and release switch.
Moving Flight Controls extended direction.
(12), raise collective stick (8) to approxi
mately 80% as shown on the IIDS, and
release switch.
CAUTION (10). Move cyclic stick (31) full forward, use

trim switch (32).
If servoactuator input lever does not over (11). Make sure longitudinal servoactuator
travel when servoactuator are at full in input lever (4) is overtraveled in the
ternal stops, damage to flight controls or retracted direction.
an out of rig condition can be the possible
cause. Do a complete inspection of bell (12). Move cyclic stick (31) full aft, use trim
cranks, brackets, control rods, and struc switch (32).
ture where brackets are attached. (13). Make sure longitudinal servoactuator
Do not move rotor flight controls through input lever (4) is overtraveled in the
their full range unless hydraulic power is extended direction.
supplied to the helicopter. (14). Put cyclic stick (31) in center position.
Cyclic stick must be centered before you (15). Move cyclic stick (31) full right, use
move collective control through its full trim switch (32).
range of travel.
(16). Make sure lateral servoactuator input
Collective control must be set at approxi lever (4) is overtraveled in the retracted
mately 80% before you move cyclic control direction.
through its full range of travel.
(17). Move cyclic stick (31) full left, use trim
NOTE: An indication of overtravel is when switch (32).
servoactuator input lever bushing in input
lever has moved from its center position (18). Make sure lateral servoactuator input
with servoactuator against its travel stop. lever (4) is overtraveled in the extended
direction.
(1). Remove swashplate forward fairing (19). Put cyclic stick (31) in center position.
(T155) (Ref. Section 53-30-00).
(2). Apply 1000 psig (6894.8 kPa) hydrau (12), lower collective stick (8) to down
lic pressure to hydraulic system stop (13), and release switch.
(21). Remove hydraulic pressure (Ref.
Section 29-00-00).
(3). Apply external electrical power, use (22). Remove external electrical power (Ref.
ground power unit (T2002) (Ref. CSP-900RMM-3).
CSP-900RMM-3).
(4). Put cyclic stick (31) in center position. (T155) (Ref. Section 06-00-00).
Page 608
H. Rotor Flight Controls Rigging Check (7). Apply external electrical power, use
(Ref. Figure 603) CSP-900RMM-3).
Special Tools (12), lower collective stick (8) to down
(Ref. CSPSPM) stop (13), and release switch.
Item Nomenclature
(9). Make sure 2.5 in. long rig pin (T501-2)
(40) can be put through bracket (39)
T2002 Ground Power Unit and bellcrank (42).
T5012 Rig Pin, 2.5 In. Long
retracted direction.
Moving Flight Controls (11). Remove 2.5 in. long rig pin (T501-2)
(40).
and release switch.
CAUTION (13). Make sure collective servoactuator
If rig pins cannot be put into bellcranks input lever (4) is overtraveled in the
when doing this procedure, damage to extended direction.
flight controls or an out of rig condition (14). Pull collective friction release switch
can be the possible cause. Do a complete (12), lower collective stick (8) to down
inspection of bellcranks, brackets, control stop (13), and release switch.
rods, and structure where brackets are
attached. (15). Make sure 2.5 in. long rig pin (T501-2)
(15) can be put through pilot lateral
NOTE: An indication of overtravel is when crank (14) and longitudinal crank (28).
lever has moved from its center position (16). If copilot flight controls are installed,
with servoactuator against its travel stop. make sure 2.5 in. long rig pin (T501-2)
(15) can be put through copilot lateral
(1). Remove swashplate forward fairing crank (14) and longitudinal crank (28).
(T155) (Ref. Section 06-00-00). (17). Make sure 5.0 in. long rig pin (T501-6)
(46) can be put through longitudinal
(2). Remove FS155.50, collective/longitudi
nal, and lateral FOD covers. bellcrank (45) and bracket (43).
(18). Remove rig pins (T501-2 and T501-6).
25-20-00). (19). Move cyclic stick (31) full forward, use
trim switch (32).
(4). Remove access panels AR138 and
AR129 (Ref. Section 06-00-00). (20). Make sure longitudinal servoactuator
(5). Disconnect bottom end of all pitch links, retracted position.
turn pitch links up, and temporarily
(21). Move cyclic stick (31) full aft, use trim
attach them to rotor head (Ref. section
switch.
62-30-00).
(22). Make sure longitudinal servoactuator
(6). Apply 1000 psig (6894.8 kPa) hydrau input lever (4) is overtraveled in the
lic pressure to hydraulic system extended direction.
(Ref. Section 29-00-00). (23). Put cyclic stick (31) in center position.
Page 609
(24). Make sure 2.5 in. long rig pin (T501-2) (2). Torque jam nuts on control rod ends
(29) can be put through pilot cyclic adjusted during this procedure to 95 -
bracket (30) and lateral crank (14). 110 in-lbs (10.73 - 11.29 Nwm) and
install safety devices.
(25). If copilot flight controls are installed,
make sure 2.5 in. long rig pin (T501-2)
(29) can be put through pilot cyclic
bracket (30) and lateral crank (14).
(26). Make sure 2.5 in. long rig pin (T501-2)
(33) can be put through bellcrank (34)
and bracket (36).
(3). Examine all areas where flight control
(27). Remove rig pins (T501-2). system components move for unwanted
(28). Move cyclic stick (31) full right, use materials.
trim switch (32).
(4). When rig pin holes are aligned after
(29). Make sure lateral servoactuator input control rods adjustment, there must be
lever (4) is overtraveled in the retracted no load in the system. You must be able
direction. to install and remove all rig pins at the
(30). Move cyclic stick (31) full left, use trim same time with a minimum of force.
switch (32).
B. Collective Controls System Rigging
(31). Make sure lateral servoactuator input (Lower)
lever (4) is overtraveled in the extended
direction. (Ref. Figure 603)
(32). Put cyclic stick (31) in center position.
(33). Remove hydraulic pressure (Ref. Special Tools
Section 29-00-00). (Ref. CSPSPM)
Item Nomenclature
CSP-900RMM-3). T2001 Hydraulic Mule
(35). Connect bottom end of all pitch links to
swashplate (Ref. section 62-30-00). T5012 Rig Pin, 2.5 In. Long

25-20-00). (1). Prepare rotor flight controls system for
(37). Install FS155.50, collective/longitudi rigging.
nal, and lateral FOD covers.
(38). Install swashplate forward fairing (T155) (Ref. Section 06-00-00).
(T155) (Ref. Section 06-00-00).
(39). Install access panels AR138 and AR129 (3). Remove collective/longitudinal FOD
(Ref. Section 06-00-00). cover.
2. Rotor Flight Controls System Rigging (4). Remove roof panels (Ref. Section
25-20-00).
A. Prepare Rotor Flight Controls System For
Rigging (5). Remove access panels AR138 and
Control Rod Thread Engage AR129 (Ref. Section 06-00-00).
WARNING ment.
(6). Disconnect bottom end of all pitch links,
(1). You must only adjust control rod ends turn pitch links up, and temporarily
adjacent to rig pin locations during attach them to rotor head (Ref. section
initial rigging procedure. 62-30-00).
Page 610
Moving Flight Controls (16). Remove rig pin (T501-2).

and release switch.
(7). Disconnect collective control rod (38). (18). Make sure collective servoactuator (2)
(8). Adjust pilot collective stick down stop retracted direction.
(13) to 0.690-0.710 in. (17.53-18.03
mm) above bracket (9).
(9). Apply external electrical power, use stop (13), and release switch.
ground power unit (T2002) (Ref. (20). Adjust collective down stop bolt (13) to
CSP-900RMM-3). get a 0.010 in. (0.254 mm) clearance
(10). Pull collective friction release switch between stop bolt (13) and collective
(12), lower collective stick (8) to down stick (8).
stop (13), and release switch. (21). Make sure control systems move freely
through their full range of travel.
NOTE: If collective stick does not touch down
stop, adjust collective friction unit link (11) (22). Make sure there is a minimum of 0.062
until collective stick touches down stop. in. (1.5 7mm) between controls and
adjacent structure. Adjust control rods
(11). Press MENU on IIDS key panel. Use adjacent to bellcranks as necessary to
arrow key to select CLP xxx.x PER get this clearance.
CENT.
If collective position sensor link
(12). With collective stick (8) against down CAUTION and collective position sensor
stop (13), adjust collective friction unit bellcrank go past center or become aligned,
link (11) until IIDS display shows CLP the collective controls can become locked or
000.0 PERCENT. position sensor can send an incorrect signal
to the VSCS system.
(13). With collective stick (8) against down
stop (13), adjust control rod (41) until (23). Pull pilot collective friction release
2.5 in. long rig pin (T501-2) (40) can be switch (12) and raise collective stick (8)
put through bracket (39) and bellcrank full up, and make sure collective
(42). position sensor link (50) and collective
position sensor bellcrank (48) do not go
(14). Apply 1000 psig (6894.8 kPa) hydrau past center or become aligned.
number 1, use hydraulic mule (T2001) (24). If necessary, adjust cockpit collective
(Ref. Section 29-00-00). control tube (49) to 8.73 in. (221.74
mm) and collective closet control rod
NOTE: An indication of overtravel is when (51) to rotate collective position sensor
servoactuator input lever bushing in input link and collective position sensor
lever has moved from its center position bellcrank so they do not go past center
with servoactuator against its travel stop. or become aligned. Do step (13). again.
Be careful when you connect (25). Make sure there is no interference
CAUTION control rod to servoactuator. between rod ends and bellcrank clevis,
Align servoactuator bearing with clevis of rod ends not adjusted out past witness
control rod, damage to bearing seal can oc holes, and all jam nuts are tight.
cur. (26). Connect lower end of pitch links (Ref.
Section 62-30-00)
(15). Adjust collective control rod (38) until it
can be connected to servoactuator (2) (27). Make sure all nuts are tight and all
with input lever (4) overtraveled in the safety devices (cotter pins, lock tabs,
retracted direction. and lockwire) are installed.
Page 611
(28). Install collective/longitudinal FOD (9). Put 2.5 in. long rig pin (T501-2) (29)
cover. through pilot lateral crank (14) and
bracket (30).
(T155) (Ref. Section 06-00-00). (10). Apply external electrical power, use
(30). Install roof panels (Ref. Section CSP-900RMM-3).
25-20-00).
(11). Move cyclic stick (31) to align rig pin
(31). Install access panels AR138 and AR129 hole in longitudinal trim actuator arm
(Ref. Section 06-00-00). (26) with rig pin hole in trim actuator
(25), use trim switch (32).
Section 29-00-00). (12). Put 2.5 in. long rig pin (T501-2) (22)
through longitudinal trim actuator arm
(33). Remove external electrical power (Ref. (26) and trim actuator (25).
CSP-900RMM-3).
(13). Move cyclic stick (31) to align rig pin
C. Cyclic Trim Actuator Rigging hole in lateral trim actuator arm (21)
(Longitudinal And Lateral) with rig pin hole in trim actuator (23),
use trim switch (32).
(Ref. Figure 603)
(14). Put 2.5 in. long rig pin (T501-2) (27)
through lateral trim actuator arm (21)
Special Tools and trim actuator (23)
(Ref. CSPSPM)
Item Nomenclature (15). Remove external electrical power (Ref.
T5012 Rig Pin, 2.5 In. Long CSP-900RMM-3).
T2002 Ground Power Unit NOTE: Gradient spring must be connected
with no compression of the spring.
Moving Flight Controls (16). Adjust length of longitudinal gradient
spring (16) as necessary and connect it
to longitudinal bellcrank (17). Torque
jamnut on gradient spring 240 in-lb
(27.12 Nwm).
(1). Remove swashplate forward fairing (17). Adjust length of lateral gradient spring
(T155) (Ref. Section 06-00-00). (20) as necessary and connect it to
lateral bellcrank assembly (18). Torque
(2). Remove access panel AR138 (Ref. jamnut on gradient spring 240 in-lb
Section 06-00-00).
(27.12 Nwm).
(3). Open access panel R128 (Ref. Section (18). Remove rig pins (T501-2).
06-00-00).
(19). Make sure there is a minimum of 0.062
(4). Disconnect longitudinal control rod in. (1.5 7mm) between controls and
(47). adjacent structure. Adjust control rods
adjacent to bellcranks as necessary to
(5). Disconnect lateral control rod (37). get this clearance.
(6). Disconnect longitudinal gradient spring Be careful when you connect
(16) at longitudinal bellcrank (17). CAUTION control rod to servoactuator.
(7). Disconnect lateral gradient spring (20) Align servoactuator bearing with clevis of
at lateral bellcrank (18). control rod, damage to bearing seal can oc
cur.
(8). Put 2.5 in. long rig pin (T501-2) (15) (20). Connect longitudinal control rod (47).
through pilot lateral crank (14) and
longitudinal crank (28). (21). Connect lateral control rod (37).
Page 612
(22). Make sure there is no interference (7). If copilot flight controls are installed,
between rod ends and bellcrank clevis, remove access cover L109 (Ref. Section
rod ends not adjusted out past witness 06-00-00).
holes, and all jam nuts are tight.
(23). Make sure all nuts are tight and all turn pitch links up, and temporarily
safety devices (cotter pins, lock tabs, attach them to rotor head (Ref. section
and lockwire) are installed. 62-30-00).
(T155) (Ref. Section 06-00-00).
(25). Install access panels AR138 (Ref.

Section 06-00-00).
(9). Disconnect longitudinal control rod
(26). Close access panel R128 (Ref. Section (47).
06-00-00).
(10). Put 2.5 in. long rig pin (T501-2) (15)
D. Longitudinal Cyclic Control System through pilot lateral crank (14) and
Rigging (Lower) longitudinal crank (28).
(11). If copilot flight controls are installed,
(Ref. Figure 603)
adjust longitudinal interconnect control
rod (19) to put 2.5 in. long rig pin
Special Tools (T501-2) (15) through copilot lateral
(Ref. CSPSPM) crank (14) and longitudinal crank (28).
Item Nomenclature
(12). Adjust longitudinal control rod (44) to
T5012 Rig Pin, 2.5 In. Long put 5.0 in. long rig pin (T501-6) (46)
T5016 Rig Pin, 5.0 In. Long through longitudinal bellcrank (45) and
T2002 Ground Power Unit bracket (43).
T2001 Hydraulic Mule (13). Apply 1000 psig (6894.8 kPa) hydrau
NOTE: You must do the collective controls sys (Ref. Section 29-00-00).
tem rigging (lower) and cyclic trim actuator
rigging (longitudinal and lateral) before you (14). Apply external electrical power, use
do this procedure. ground power unit (T2002) (Ref.
CSP-900RMM-3).
(1). Prepare rotor flight controls system for
rigging. (15). Pull collective friction release switch
(2). Remove swashplate forward fairing stop (13), and release switch.
(T155) (Ref. Section 06-00-00).
(16). Put a 2.5 in. long rig pin (T501-2) (40)
(3). Remove FS155.50, collective/longitudi through collective bell crank (42) and
nal, and lateral FOD covers. bracket (39).
(17). Align rig pin hole in lateral bellcrank
(4). Remove roof panels (Ref. Section (34) and bracket (36) and install 2.5 in.
25-20-00). long rig pin (T501-2) (33).
(5). Remove access panels AR138 and (18). Remove rig pins from longitudinal
AR129 (Ref. Section 06-00-00). controls.
(6). Remove access panel R128 (Ref. Section (19). Move cyclic stick (31) full forward, use
06-00-00). trim switch (32).
Page 613
NOTE: An indication of overtravel is when (33). Remove external electrical power (Ref.
servoactuator input lever bushing in input CSP-900RMM-3).
lever has moved from its center position
with servoactuator against its travel stop. (34). Remove hydraulic pressure (Ref.
Section 29-00-00).
Be careful when you connect (35). Connect lower end of pitch links (Ref.
CAUTION control rod to servoactuator. Section 62-30-00).
Align servoactuator bearing with clevis of
control rod, damage to bearing seal can oc E. Lateral Cyclic Control System Rigging
cur. (Lower)
(20). Adjust longitudinal control rod (47) (Ref. Figure 603)

until it can be connected to servoactua
tor (3) with input lever (4) overtraveled Special Tools
in the retracted direction. (Ref. CSPSPM)
Item Nomenclature
(21). Move cyclic stick (31) full aft, use trim T2002 Ground Power Unit
switch (32).
(22). Make sure longitudinal servoactuator T5012 Rig Pin, 2.5 In. Long
(3) input lever (4) is overtraveled in the T5016 Rig Pin, 5.0 In. Long
extended direction.
(23). Remove rig pins (T501-2) and NOTE: You must do the collective controls sys
(T501-6). tem rigging (lower) and cyclic trim actuator
rigging (longitudinal and lateral) before you
(24). Make sure there is a minimum of 0.062 do this procedure.
in. (1.5 7mm) between controls and
adjacent structure. Adjust control rods
rigging.
get this clearance. (2). Remove swashplate forward fairing
(T155) (Ref. Section 06-00-00).
(25). Make sure there is no interference
between rod ends and bellcrank clevis, (3). Remove FS155.50, collective/longitudi
rod ends not adjusted out past witness nal, and lateral FOD covers.
holes, and all jam nuts are tight. (4). Remove roof panels (Ref. Section
25-20-00).
(26). Make sure all nuts are tight and all
safety devices (cotter pins, lock tabs, (5). Disconnect bottom end of all pitch links,
and lockwire) are installed. turn pitch links up, and temporarily
(27). Put cyclic stick (31) in center position. 62-30-00).
(28). Install FS155.50, collective/longitudi (6). Remove access panels AR138 and
nal, and lateral FOD covers. AR129 (Ref. Section 06-00-00).
(29). Install swashplate forward fairing (7). If copilot flight controls are installed,
(T155) (Ref. Section 06-00-00). remove access cover L109 and R128
(30). Install access panels AR138 and AR129
(31). Close access panel R128 (Ref. Section
06-00-00).
(32). Install roof panels (Ref. Section (8). Apply 1000 psig (6894.8 kPa) hydrau
25-20-00) lic pressure to hydraulic system
Page 614
number 1, use hydraulic mule (T2001) Be careful when you connect

(Ref. Section 29-00-00). CAUTION control rod to servoactuator.
(9). Apply external electrical power, use control rod, damage to bearing seal can oc
ground power unit (T2002) (Ref. cur.
CSP-900RMM-3).
(21). Adjust lateral control rod (37) until it
can be connected to servoactuator (1)
with input lever (4) overtraveled in the
retracted direction.
stop (13), and release switch.
(22). Move cyclic stick (31) full left, use trim
(11). Put a 2.5 in. long rig pin (T501-2) (40) switch (32).
through collective bell crank (42) and
bracket (39). (23). Make sure lateral servoactuator (1)
(12). Put 5.0 in. long rig pin (T501-6) (46) extended direction.
through longitudinal bellcrank (45) and (24). Remove rig pins.
bracket (43).
(25). Make sure there is a minimum of 0.062
(13). Disconnect hydraulic mule (T2001) in. (1.5 7mm) between controls and
from helicopter (Ref. Section 29-00-00). adjacent structure. Adjust control rods
(14). Disconnect lateral control rod (37). get this clearance.
(26). Make sure there is no interference
(15). Align pilot lateral crank (14) and between rod ends and bellcrank clevis,
bracket (30), install 2.5 in. long rig pin rod ends not adjusted out past witness
(T501-2) (29). holes, and all jam nuts are tight.
(16). If copilot flight controls are installed, (27). Make sure all nuts are tight and all
adjust lateral interconnect control rod safety devices (cotter pins, lock tabs,
(24) to put 2.5 in. long rig pin (T501-2) and lockwire) are installed.
(29) through copilot lateral crank (14) (28). Put cyclic stick (31) in center position.
and bracket (30).
(29). Install FS155.50, collective/longitudi
(17). Adjust lateral control rod (35) until 2.5 nal, and lateral FOD covers.
in. long rig pin (T501-2) (33) can be put
through bellcrank (34) and Bracket (30). Install swashplate forward fairing
(36). (T155) (Ref. Section 06-00-00).
(31). Install access panels AR138 and AR129
(18). Apply 1000 psig (6894.8 kPa) hydrau (Ref. Section 06-00-00).
number 1, use hydraulic mule (T2001) (32). If removed, install access panel L109
(Ref. Section 29-00-00). and R128 (Ref. Section 06-00-00).
(19). Remove rig pins from lateral controls. 25-20-00)
(20). Move cyclic stick (31) full right, use (34). Remove external electrical power (Ref.
trim switch (32). CSP-900RMM-3).
NOTE: An indication of overtravel is when Section 29-00-00).
lever has moved from its center position (36). Connect lower end of pitch links (Ref.
with servoactuator against its travel stop. Section 62-30-00).
Page 615
7 4 OVERTRAVEL IN EXTENDED 1
DIRECTION (UP)
6
5
OVERTRAVEL IN RETRACTED
DIRECTION (DOWN)
SERVOACTUATOR
TYPICAL
8
13
PILOT COLLECTIVE
32 COPILOT TYPICAL
12
REF. 9
11
(NOTE 1)
10
(NOTE 1)
31 9
PILOT CYCLIC
COPILOT TYPICAL 30
14
17
15
29
18
16 (NOTE 2)
19
26
20 (NOTE 2)
27 21 (NOTE 2)
26 (NOTE 2)
25 (NOTE 2) 24 22
NOTES: 23 (NOTE 2)
1. ONLY PILOT COLLECTIVE HAS A COLLECTIVE FRICTION UNIT.
2. ONLY PILOT CYCLIC HAS TRIM ACTUATORS AND GRADIENT SPRINGS. 9G67-035-1A
Figure 603. Rotor Flight Controls (Lower) (Sheet 1 of 2)
Page 616
46 47 42
45
38
44 37
43
39
LONGITUDINAL CYCLIC 36
40
41
COLLECTIVE
51 35
50
49 33
34
LATERAL CYCLIC
48
9G67-035-2A
1. LATERAL SERVOACTUATOR 27. RIG PIN
2. COLLECTIVE SERVOACTUATOR 28. LONGITUDINAL CRANK
3. LONGITUDINAL SERVOACTUATOR 29. RIG PIN
4. INPUT LEVER 30. BRACKET
5. INPUT BEARING 31. CYCLIC STICK
6. STOP BUSHING 32. CYCLIC STICK TRIM SWITCH
7. FEEDBACK LINK 33. RIG PIN
8. COLLECTIVE STICK 34. LATERAL BELLCRANK
9. COLLECTIVE STICK BRACKET 35. LATERAL CONTROL ROD
10. COLLECTIVE FRICTION UNIT 36. LATERAL BELLCRANK BRACKET
11. COLLECTIVE FRICTION UNIT LINK
37. LATERAL SERVOACTUATOR CONTROL ROD
12. COLLECTIVE FRICTION RELEASE SWITCH
38. COLLECTIVE SERVOACTUATOR CONTROL ROD
13. COLLECTIVE STICK DOWN STOP
39. COLLECTIVE BELLCRANK BRACKET
14. LATERAL CRANK
40. RIG PIN
15. RIG PIN
41. COLLECTIVE CONTROL ROD
16. LONGITUDINAL GRADIENT SPRING
17. LONGITUDINAL BELLCRANK 42. COLLECTIVE BELLCRANK
18. LATERAL BELLCRANK 43. LONGITUDINAL BELLCRANK BRACKET
19. LONGITUDINAL INTERCONNECT CONTROL ROD 44. LONGITUDINAL CONTROL ROD
20. LATERAL GRADIENT SPRING 45. LONGITUDINAL BELLCRANK
21. LATERAL TRIM ACTUATOR ARM 46. RIG PIN
22. RIG PIN 47. LONGITUDINAL SERVOACTUATOR CONTROL ROD
23. LATERAL TRIM ACTUATOR 48. COLLECTIVE POSITION SENSOR BELLCRANK
24. LATERAL INTERCONNECT CONTROL ROD 49. COCKPIT COLLECTIVE CONTROL TUBE
25. LONGITUDINAL TRIM ACTUATOR 50. COLLECTIVE POSITION SENSOR LINK
26. LONGITUDINAL TRIM ACTUATOR ARM 51. COLLECTIVE CLOSET CONTROL ROD
Figure 603.Rotor Flight Controls (Lower) (Sheet 2 of 2)
Page 617
F. Collective Controls Mixer Rigging (9). Put inclinometer (T203) against static
mast (1) at position (6). Make a record
(Ref. Figure 604) of the angle
(10). Put inclinometer (T203) on top of
Consumable Materials collective mixer bellcrank (4) at position
(Ref. CSPSPM) (5). Make a record of the angle
Item Nomenclature
(11). Angle between static mast (1) and top
C702 Lockwire of collective mixer bellcrank (4). Angle
must be 101.2-101.4 degrees.
Special Tools CAUTION

(Ref. CSPSPM) All servoactuator piston rod end adjust
Item Nomenclature ments must be made with the piston
T2001 Hydraulic Mule away from its internal travel stops.
T2002 Ground Power Unit Servoactuator piston rod end must not be
T203 Inclinometer more than 2.181 in. (55.397 mm) above
top of servoactuator piston.
(12). If necessary, adjust collective servoac
(1). Prepare rotor flight controls system for tuator piston rod end (13) as follows:
rigging.
(a). Remove lockwire from nut (12).
(2). Remove swashplate forward fairing (b). Loosen nut (12).
(T155) (Ref. Section 06-00-00).
(c). Lift input lever (7) to move servoac
(3). Disconnect bottom end of all pitch links, tuator piston (14) away from its
turn pitch links up, and temporarily internal stop.
62-30-00). (d). Lift lock ring (11) and carefully turn
servoactuator piston (14), use flats at
Moving Flight Controls top of piston.
NOTE: Turn piston left to lengthen (decrease
angle) or right to shorten (increase angle).
(e). Push down on servoactuator input
lever (7) until servoactuator piston
(4). Disconnect collective control rod (2). (14) is fully retracted.
(5). Apply external electrical power, use (f). If angle between the static mast (1)
ground power unit (T2002) (Ref. and top of collective mixer bellcrank
CSP-900RMM-3). (4) is not 101.2-101.4 degrees, do
steps (c). thru (e). again.
(6). Apply 1000 psig (6894.8 kPa) hydrau (g). Make sure servoactuator rod end (13)
lic pressure to hydraulic system is not more than 2.181 in. (55.397
number 1, use hydraulic mule (T2001) mm) above top of servoactuator
(Ref. Section 29-00-00). piston (14).
(7). Pull collective friction release switch (h). Tighten nut (12).
(16), lower collective stick (17) to down (i). Safety nut (12), use lockwire (C702).
stop (15), and release switch.
NOTE: An indication of overtravel is when
(8). Push down on servoactuator input lever servoactuator input lever bushing in input
(7) until servoactuator piston (14) is lever has moved from its center position
fully retracted. with servoactuator against its travel stop.
Page 618
Be careful when you connect is overtraveled in the extended direc

CAUTION control rod to servoactuator. tion.
control rod, damage to bearing seal can oc (17). Make sure angle between static mast
cur. (1) and top of collective mixer bellcrank
(4) is 90.3-92.1 degrees.
(13). Adjust collective control rod (2) until it (18). Make sure there is no interference
can be connected to servoactuator (3) between rod ends and bellcrank clevis,
with input lever (7) overtraveled in the rod ends not adjusted out past witness
retracted direction. holes, and all rod end nuts are tight.
(14). Adjust collective down stop bolt (15) to (19). Connect lower end of pitch links (Ref.
get a 0.010 in. (0.254 mm) clearance Section 62-30-00)
between stop bolt (15) and collective
stick (17). (20). Make sure all nuts are tight and all
safety devices (cotter pins, lock tabs,
(15). Pull collective friction release switch and lockwire) are installed.
and release switch. (21). Install swashplate forward fairing
(T155) (Ref. Section 06-00-00).
Collective servoactuator must (22). Remove hydraulic pressure (Ref.
CAUTION overtravel in its full extended Section 29-00-00).
and full retracted positions.
(16). Make sure servoactuator input lever (7) CSP-900RMM-3).
Page 619
2.181 IN (55.397 mm)

MAXIMUM (NOTE 2)
13
10 7
12
11 9 6
14 8
1
NOTE 1
DIRECTION (DOWN)
OVERTRAVEL IN EXTENDED
DIRECTION (UP)
17
2
16
15
NOTES:
1. COLLECTIVE DOWN ANGLE 101.2-101.4 DEGREES.
COLLECTIVE UP ANGLE 90.3-92.1 DEGREES.
2. SERVOACTUATOR PISTON ROD END MUST NOT BE MORE THAN
2.181 IN (55.397 mm) ABOVE TOP OF SERVOACTUATOR PISTON. 9G67-014C
1. STATIC MAST 10. FEEDBACK LINK
2. COLLECTIVE SERVOACTUATOR CONTROL ROD 11. LOCK RING
3. COLLECTIVE SERVOACTUATOR 12. NUT
4. COLLECTIVE MIXER BELLCRANK 13. ROD END
5. COLLECTIVE INCLINOMETER POSITION 14. SERVOACTUATOR PISTON
6. STATIC MAST INCLINOMETER POSITION 15. COLLECTIVE DOWN STOP
7. INPUT LEVER 16. COLLECTIVE FRICTION RELEASE SWITCH
8. INPUT BEARING 17. COLLECTIVE STICK
9. STOP BUSHING
Figure 604. Collective Controls Mixer Rigging
Page 620
G. Longitudinal Cyclic Mixer Rigging (8). Install 2.5 in. long rig pin (T501-2) (21)
through bellcrank (19) and bracket (20).
(Ref. Figure 605)
(9). move cyclic stick (24) full forward, use
trim switch (25).
(Ref. CSPSPM) (10). Disconnect control rod (5).
Item Nomenclature
(11). Push down on servoactuator input lever
C702 Lockwire (11) until servoactuator piston (15) is
fully retracted.
(12). Put inclinometer (T203) against static
Special Tools mast (1) at position (10). Make a record
(Ref. CSPSPM) of the angle
Item Nomenclature
(13). Put inclinometer (T203) on top of
longitudinal mixer bellcrank (8) at
T2001 Hydraulic Mule position (7). Make a record of the angle
of longitudinal mixer bellcrank (8).
NOTE: You must do the collective controls sys Angle must be 112.1-112.3 degrees.
rigging (longitudinal and lateral) before you CAUTION
do this procedure.
All servoactuator piston rod end adjust
(1). Prepare rotor flight controls system for ments must be made with the piston
rigging. away from its internal travel stops.
Servoactuator piston rod end must not be
more than 2.181 in. (55.397 mm) above
(T155) (Ref. Section 06-00-00).
(3). Remove collective/longitudinal FOD (15). If necessary, adjust longitudinal
cover. servoactuator piston rod end (18) as
follows:
turn pitch links up, and temporarily (a). Remove lockwire from nut (17).
62-30-00). (b). Loosen nut (17).
Moving Flight Controls (c). Lift input lever (11) to move servoac
tuator piston (15) away from its
internal stop.
(d). Lift lock ring (16) and carefully turn
(5). Apply external electrical power, use top of piston.
ground power unit (T2002) (Ref. NOTE: Turn piston left to lengthen (decrease
CSP-900RMM-3). angle) or right to shorten (increase angle).
(6). Apply 1000 psig (6894.8 kPa) hydrau (e). Push down on servoactuator input
lic pressure to hydraulic system lever (11) until servoactuator piston
number 1, use hydraulic mule (T2001) (15) is fully retracted.
(f). If angle between the static mast (1)
(7). Pull collective friction release switch and top of longitudinal mixer bell
(23), lower collective stick (22) to full crank (8) is not 112.1-112.3 degrees,
down, and release switch. do steps (c). thru (e). again.
Page 621
(g). Make sure servoactuator rod end (18) (19). Make sure angle between static mast
is not more than 2.181 in. (55.397 (1) and top of longitudinal mixer
mm) above top of servoactuator bellcrank (8) is 99.97-100.07 degrees.
piston (15).
(20). Remove 2.5 in. long rig pin (T501-2)
(h). Tighten nut (17).
(21) from bellcrank (19) and bracket
(i). Safety nut (17), use lockwire (C702). (20).
NOTE: An indication of overtravel is when (21). Make sure there is no interference
servoactuator input lever bushing in input between rod ends and bellcrank clevis,
lever has moved from its center position rod ends not adjusted out past witness
with servoactuator against its travel stop. holes, and all rod end nuts are tight.
Be careful when you connect
CAUTION control rod to servoactuator. (22). Connect lower end of pitch links (Ref.
Align servoactuator bearing with clevis of Section 62-30-00)
control rod, damage to bearing seal can oc
cur. (23). Make sure all nuts are tight and all
(16). Adjust longitudinal control rod (5) until
and lockwire) are installed.
it can be connected to servoactuator (6)
retracted direction. (24). Install collective/longitudinal FOD
cover.
(17). move cyclic stick (24) full aft, use trim
switch (25). (25). Install swashplate forward fairing
(T155) (Ref. Section 06-00-00).
Longitudinal servoactuator
CAUTION must overtravel in its full ex
tended and full retracted positions. (26). Remove hydraulic pressure (Ref.
Section 29-00-00).
(18). Make sure servoactuator input lever
(11) is overtraveled in the extended (27). Remove external electrical power (Ref.
direction. CSP-900RMM-3).
Page 622
H. Lateral Cyclic Mixer Rigging (8). Install 2.5 in. long rig pin (T501-2) (21)
through bellcrank (19) and bracket (20).
(Ref. Figure 605)
(9). move cyclic stick (24) full left, use trim
switch (25).
(Ref. CSPSPM) (10). Disconnect control rod (4).
Item Nomenclature
(11). Lift servoactuator input lever (11) until
C702 Lockwire servoactuator piston (15) is fully in the
extended direction.
(12). Put inclinometer (T203) against static
Special Tools
mast (1) at position (10). Make a record
(Ref. CSPSPM)
of the angle
Item Nomenclature
T2002 Ground Power Unit (13). Put inclinometer (T203) on top of
T2001 Hydraulic Mule lateral mixer bellcrank (2) at position
(9). Make a record of the angle
of lateral mixer bellcrank (2). Angle
NOTE: You must do the collective controls sys must be 96.5 to 96.9 degrees.
rigging (longitudinal and lateral) before you
do this procedure. CAUTION
All servoactuator piston rod end adjust
ments must be made with the piston
rigging.
away from its internal travel stops.
(2). Remove swashplate forward fairing Servoactuator piston rod end must not be
(T155) (ref. Section 06-00-00). more than 2.181 inch (55.40 mm) above
(3). Remove collective/longitudinal FOD
cover. (15). If necessary, adjust lateral servoactua
tor piston rod end (18) as follows:
turn pitch links up, and temporarily (a). Remove lockwire from nut (17).
attach them to rotor head (ref. Section (b). Loosen nut (17).
62-30-00).
(c). Lower input lever (11) to move
Moving Flight Controls servoactuator piston (15) away from
its internal stop.
(d). Lift lock ring (16) and carefully turn
top of piston.
ground power unit (T2002) (ref. NOTE: Turn piston left to lengthen (decrease
CSP-900RMM-3). angle) or right to shorten (increase angle).
(6). Apply 1000 psig (6894.8 kPa) hydrau (e). Lift servoactuator input lever (11)
lic pressure to hydraulic system until servoactuator piston (15) is
number 1, use hydraulic mule (T2001) fully in the extended direction.
(f). If angle between the static mast (1)
(7). Pull collective friction release switch and top of lateral mixer bellcrank (2)
(23), lower collective stick (22) to full is not 96.5 to 96.9 degrees, do steps
down, and release switch. (c). thru (e). again.
Page 623
(g). Make sure servoactuator rod end (18) (19). Make sure angle between static mast
is not more than 2.181 inch (55.40 (1) and top of lateral mixer bellcrank (2)
mm) above top of servoactuator is 101.6 to 102.0 degrees.
piston (15).
(20). Remove 2.5 in. long rig pin (T501-2)
(h). Tighten nut (17).
(21) from bellcrank (19) and bracket
(i). Safety nut (17) with lockwire (C702). (20).
NOTE: An indication of overtravel is when (21). Make sure there is no interference
servoactuator input lever bushing in input between rod ends and bellcrank clevis,
lever has moved from its center position rod ends not adjusted out past witness
with servoactuator against its travel stop. holes, and all rod end nuts are tight.
Be careful when you connect
CAUTION control rod to servoactuator. (22). Connect lower end of pitch links (ref.
Align servoactuator bearing with clevis of Section 62-30-00)
control rod, damage to bearing seal can oc
cur. (23). Make sure all nuts are tight and all
(16). Adjust lateral control rod (4) until it
and lockwire) are installed.
can be connected to servoactuator (3)
extended direction. (24). Install collective/longitudinal FOD
cover.
(17). Move cyclic stick (24) full right with
trim switch (25). (25). Install swashplate forward fairing
(T155) (ref. Section 06-00-00).
Longitudinal servoactuator
CAUTION must overtravel in its full ex
tended and full retracted positions. (26). Remove hydraulic pressure (ref. Section
29-00-00).
(18). Make sure servoactuator input lever
(11) is overtraveled in the retracted (27). Remove external electrical power (ref.
direction. CSP-900RMM-3).
Page 624
2.181 IN (55.397 mm)

MAXIMUM (NOTE 3)
18
14 11
17
16 10
13
15 12 1
DIRECTION (DOWN) 8
9
7
NOTE 2
NOTE 1
OVERTRAVEL IN EXTENDED
SERVOACTUATOR DIRECTION (UP)
TYPICAL 2
25 6
3
5
19
24
4
20
21 COLLECTIVE
23
22
NOTES:
1. LONGITUDINAL FORWARD ANGLE 112.1-112.3 DEGREES. LONGITUDINAL AFT ANGLE 99.97-100.07 DEGREES. 9G67-020
2. LATERAL RIGHT ANGLE 101.6-102.0 DEGREES. LATERAL LEFT ANGLE 96.5-96.9 DEGREES.
3. SERVOACTUATOR PISTON ROD END MUST NOT BE MORE THAN 2.181 IN (55.397 mm) ABOVE TOP OF SERVOACTUATOR PISTON.
1. STATIC MAST 14. FEEDBACK LINK

2. LATERAL MIXER BELLCRANK 15. SERVOACTUATOR PISTON
3. LATERAL SERVOACTUATOR 16. LOCK RING
4. LATERAL SERVOACTUATOR CONTROL ROD 17. NUT
5. LONGITUDINAL SERVOACTUATOR CONTROL ROD 18. ROD END
6. LONGITUDINAL SERVOACTUATOR 19. COLLECTIVE CONTROLS BELLCRANK
7. LONGITUDINAL INCLINOMETER POSITION 20. COLLECTIVE CONTROLS BELLCRANK BRACKET
8. LONGITUDINAL MIXER BELLCRANK 21. RIG PIN
9. LATERAL INCLINOMETER POSITION 22. COLLECTIVE STICK
10. STATIC MAST INCLINOMETER POSITION 23. COLLECTIVE FRICTION RELEASE SWITCH
11. INPUT LEVER 24. CYCLIC STICK
12. INPUT BEARING 25. CYCLIC STICK TRIM SWITCH
13. STOP BUSHING
Figure 605. Cyclic Mixer Rigging
Page 625
3. Cyclic Trim Actuator Resistor Value Moving Flight Controls
(Ref. Figure 606)
NOTE: This procedure finds the resistor value

for correct trim actuator operation. (c). move cyclic stick forward, use trim
switch.
Special Tools (d). Make sure trim actuator moves cyclic
(Ref. CSPSPM) stick forward.
Item Nomenclature
(e). move cyclic stick aft, use trim switch.
T2001 Hydraulic Mule (f). Make sure trim actuator moves cyclic
T1003 Digital Multimeter, Portable stick aft.
(g). If trim actuator moves in the two
directions, go to step (k).
CAUTION (h). If trim actuator does not move in one
of the two directions, install resistor
Make sure all unnecessary circuit break
with lower resistance value and do
ers are out.
steps (b). thru (f). again.
Make sure all electrical switches on cen
ter console control panels are in the OFF (i). If trim actuator does not move after
position. lowest resistance resistor is installed,
do a test for an open circuit condition
Collective control must be set at approxi and a short circuit condition (Ref.
mately 80% before you move cyclic control CSP-900RMM-3, Section 98-40-00
through its full range of travel. and CSP-SPM, Section 20-60-00).
(1). Apply 1000 psig (6894.8 kPa) hydrau (j). If there are no short or open circuit
lic pressure to hydraulic system conditions, replace trim actuator and
number 1, use hydraulic mule (T2001) go to step (a).
(Ref. Section 29-00-00). (k). Make sure the time to trim from
forward trim motor stop to aft trim
(2). Apply external electrical power, use motor stop is 15-23 seconds.
CSP-900RMM-3). (l). Make sure the time to trim from aft
trim motor stop to forward trim
(3). Push in GCU L and GCU R circuit motor stop is 15-23 seconds.
breakers located on the essential bus
circuit breaker panel. (m). Put cyclic stick in center position.
(n). Pull collective friction release switch,
(4). Pull collective friction release switch, lower collective stick to full down,
raise collective stick to approximately and release switch.
80% as shown on the IIDS, and release
switch. (o). Remove hydraulic pressure (Ref.
Section 29-00-00).
(5). Find value for longitudinal trim
actuator as follows: (p). Remove external electrical power
(Ref. CSP-900RMM-3).
(a). Connect highest value resistor (2) to (q). Install resistor (2), washers (3), and
longitudinal trim resistor wires (1). screws (4). Torque screws.
(b). Push in TRIM circuit breaker on the (6). Find value for lateral trim actuator as
essential bus circuit breaker panel. follows:
Page 626
(a). Connect highest value resistor (2) to (j). If there are no short or open circuit
longitudinal trim resistor wires (1). conditions, replace trim actuator and
go to step (a).
(b). Push in TRIM circuit breaker on the
essential bus circuit breaker panel.
(k). Make sure the time to trim from
(c). move cyclic stick left, use trim right trim motor stop to left trim
switch. motor stop is 15-23 seconds.
(d). Make sure trim actuator moves cyclic
stick left. (l). Make sure the time to trim from left
trim motor stop to right trim motor
(e). move cyclic stick right, use trim stop is 15-23 seconds.
switch.
(f). Make sure trim actuator moves cyclic (m). Put cyclic stick in center position.
stick right.
(g). If trim actuator moves in the two (n). Pull collective friction release switch,
directions, go to step (k). lower collective stick to full down,
and release switch.
(h). If trim actuator does not move in one
of the two directions, install resistor
with lower resistance value and do (o). Remove hydraulic pressure (Ref.
steps (b). thru (f). again. Section 29-00-00).
(i). If trim actuator does not move after (p). Remove external electrical power
lowest resistance resistor is installed, (Ref. CSP-900RMM-3).
do a test for an open circuit condition
and a short circuit condition (Ref.
CSP-900RMM-3, Section 98-40-00 (q). Install resistor (2), washers (3), and
and CSP-SPM, Section 20-60-00). screws (4). Torque screws.
1 (4 PL)
3 (4 PL)
4 (4 PL)
2 (2 PL)
VIEW LOOKING DOWN

IN RIGHT AVIONICS BAY
9G67-042A
1. RESISTOR WIRE 3. WASHER
2. RESISTOR 4. SCREW
Figure 606. Resistor Installation
Page 627
4. Trim Actuator P/N 900C3010004107 (c). Connect digital multimeter (T1003)

Electronic Stop Test between the two parts of wire
AFCS-284A22.
(Ref. Figure 607)
(3). Test electronic stop as follows:
Special Tools Moving Flight Controls
(Ref. CSPSPM)
Item Nomenclature
T1003 Digital Multimeter, Portable (a). Apply 1000 psig (6894.8 kPa)
hydraulic pressure to hydraulic
system number 1, use hydraulic mule
(T2001) (Ref. Section 29-00-00).
(Ref. CSPSPM) The two wires will have 28
Item Nomenclature WARNING Vdc. Do not touch conduc
C820 Junction, Splice tors or short conductors to ground.
(b). Apply external electrical power, use
NOTE: The splice (C820) is installed for subse ground power unit (T2002) (Ref.
quent tests. If the splice is installed, discon CSP-900RMM-3).
nect one wire and go to step (c).
(c). Pull collective friction release switch,
(1). Install splice in helicopters without raise collective stick to approximately
autopilot as follows: 80% as shown on the IIDS, and
release switch.
(a). Cut wire C1C22 no less than 3 in. (76
mm) from terminal block TB3-10K NOTE:
on A612 forward interconnect panel. The trim actuator stop is past the me
chanical servoactuator stop.
(b). Install splice (C820) on wire con
nected to TB3-10K (Ref. CSP-SPM, The amperage must go to zero when trim
Section 20-60-00). actuator is at its electronic stop.
(d). Look at amperage on digital multi
(c). Connect digital multimeter (T1003)
meter (T1003) while you move cyclic
between the two parts of wire C1C22.
stick to its longitudinal forward and
(2). Install splice on helicopters with aft electronic stop, use trim switch.
autopilot system as follows: (e). Look at amperage on digital multi
NOTE: Refer to Honeywell Rotorcraft Mainte meter (T1003) while you move cyclic
nance Manual 006-00757-0000, Drawing stick to its lateral left and right
numbers 159-08140-2000, sheet 8, the 4 stops, use trim switch.
tube configuration or 159-08140-2001, (f). If amperage does not go to zero when
sheet 8, the 2 tube configuration. trim actuator is at its electronic stop,
(a). Cut wire AFCS-284A22 no less than replace trim actuator.
3 in. (76 mm) from connector P128 (g). Put cyclic stick in center position.
that connects to the A601 essential
bus circuit breaker panel. (h). Pull collective friction release switch,
lower collective stick to 0% as shown
(b). Install splice (C820) on wire con on the IIDS, and release switch.
nected to P128 (Ref. CSP-SPM,
Section 20-60-00 and Honeywell (i). Remove hydraulic pressure (Ref.
wire diagrams). Section 29-00-00).
Page 628
(j). Remove external electrical power (k). Connect cut wire to splice (C820)
(Ref. CSP-900RMM-3). (Ref. CSP-SPM, Section 20-60-00
and Honeywell wire diagrams).
LOOKING INBOARD
RIGHT SIDE
9G67-060
Figure 607. Forward Interconnect Panel (A612) Terminal Board 3
Page 629
Page 630
Section
671020
Collective Control
Module / Cyclic Grip
COLLECTIVE CONTROL MODULE/CYCLIC GRIP

FAULT ISOLATION
The following troubleshooting procedures are a Troubleshooting tables should be used with the
brief summary of Collective Control Module simplified system schematics, electrical wiring
(collective grip) and Cyclic Grip faults, which diagrams, serviceability checks and other
may be encountered (Ref. Table 101). detailed procedures referred to in this and
Comprehensive wiring diagrams are available
in the Rotorcraft Maintenance Manual
Table 101. Collective Control Module/Cyclic Grip Troubleshooting
Specific action does not Faulty wiring Isolate damage to component 671020
occur when switch is wiring (Ref. Figure 101,
activated Figure 102)
Repair wiring 980000
Troubleshoot system wiring 980000
Faulty switch Replace specific switch 671020
Auto Pilot feature on cyclic Incorrect configuration cyclic Change to latest configuration 671020
grip does not operate grip 105 cyclic grip (Ref.
Figure 101)
Faulty switch Check switch and replace if 671020
required
Float Deploy feature on cyclic Incorrect configuration cyclic Change to latest configuration 671020
grip does not operate grip 105 cyclic grip (Ref.
properly Figure 101)
Faulty switch Check switch and replace if 671020
required
Page 101
67-10-20 Original
S2
S3 S5
S1
S4
A218-167578-00
NC S5 A218-067680-00
L S5
H FLOAT
FLOAT H
DEPLOY DEPLOY
L
(D)
(D)
A218-067679-00 A218-067679-00
T AUTO S4 T AUTO S4
PILOT PILOT
S DISC S DISC
A218-067573-02 A218-067573-02
V S3 V S3
CARGO CARGO
U HOOK REL U HOOK REL
A218-101117-02 A218-101117-02
Z Z S2
DN FWD
PITCH/ PITCH/
ROLL ROLL
LT RT LT RT
(A) TRIM (A) TRIM
D D
UP AFT
E E
F S2 F
A218-167576-02
XMIT S1 XMIT S1
NO NO
A A
X X
B B
NC NC
(J) (J)
Y Y
NO NO
W ICS W ICS
900C3010064-103 900C3010064-105
STANDARD GRIP ALTERNATE GRIP WIRING
REQUIRED FOR FLOAT AND
AUTO PILOT INSTALLED OPTIONS
9G67043
Figure 101. Cyclic Grip Switch Wiring
Page 102
Original 67-10-20
S1
COLLECTIVE FRICTION
RELEASE SWITCH
EEC RESET
S2
OFF GATE RELEASE S9
S7
GO AROUND
FOR FUTURE USE S4
S8
RADIO
TUNING
S5
S6
S2
S7
S10
S3 S8
S10
AUTOPILOT YAW S9
S1
S6
SEARCH LIGHT EARLY CONFIG
S5
LIGHTS
HIGH S3
1
2 3 RPM
5 4
SWITCH
6
NORM
9G670271
Figure 102. Collective Control Module Switch Wiring (Sheet 1 of 3)
Page 103
67-10-20 Original
S5
S6
S2 S7
S8
S3
S9
900 CONFIG
(OFF GATE REMOVED)
9G670273
Page 104
Original 67-10-20
S2
S5
S6
S7
S8
S3
S9
902 CONFIG-115
S5 S6
S7
S2
S9
S10
S8
S3
902 CONFIG-117
9G670272

67-10-20 Original
COLLECTIVE CONTROL MODULE/CYCLIC GRIP

1. Collective Control Module C. Collective Control Module Reassemble
A. Collective Control Module Removal (Ref. Figure 402)
(Ref. Figure 402)
Power Off (Ref. CSPSPM)
Item Nomenclature
(1). Verify all power is removed from (1). Install specific switch for replacement.
(2). Secure with nuts (3) or other attaching
(2). Loosen connector P1 (1) collar and hardware to switchplate cover (1) or
remove electrical connector P1 (1) from collective control module (4) assembly.
bottom of collective control module (2).
(3). Install any set screws that may secure
(3). Align holes in throttle twist grip (3) as specific switches to switchplate.
required and remove attachment screw
(4). (4). Solder wires to new switch.
(4). Remove control module (2) from end of (5). Install screws (2) attaching switchplate
collective control stick assembly (5). cover (1) to control module (4).
B. Collective Control Module Disassemble Silicone Compound (C221)
(Ref. Figure 402)
NOTE: If control module warranty has expired,
switches may be replaced by owner/opera
tor. (6). Cover screw (2) heads with silicone
compound (C221).
(1). Remove collective control module
assembly (4) from collective control (7). Smooth compound flush with switch
stick. plate.
(2). Remove bonding compound (C221) from (8). Install control module (4) on collective
heads of switchplate screws (2). stick assembly.
(3). Remove screws (2) and remove switch D. Collective Control Module Installation
plate cover (1).
(Ref. Figure 402)
(4). Unsolder applicable wires if removing
any switches. Power Off
(5). Remove any set screws that may secure
specific switches to switchplate.
(6). Unscrew any nuts (3) or other attach
ing hardware that secures switches to (1). Verify all power is removed from
cover (1) or control module assembly aircraft (Ref. Section 96-00-00).
(4).
(7). Remove specific switch for replacement. CSP-SPM).
Page 401
67-10-20 Original
(3). Align and install collective control (5). Align and install electrical connector P1
module (2) onto end of collective control (1) on bottom of control module (2).
stick assembly (5). Tighten connector P1 (1) collar.
(6). Test electrical bond between points A
and B.
(4). Align holes in throttle twist grip (3) as
required and install attachment screw (7). Restore power to aircraft (Ref. Section
(4). Torque screw (4). 96-00-00).
3
4
5
2
POINT A
POINT B
9G67030
1. CONNECTOR P1 4. SCREW
2. COLLECTIVE CONTROL MODULE 5. COLLECTIVE CONTROL STICK ASSEMBLY
3. TWIST GRIP
Figure 401. Collective Control Module Installation
4
3
1
2 (4 PL)
9G67045
1. SWITCHPLATE COVER 3. NUT

2. SCREW 4. COLLECTIVE CONTROL MODULE ASSEMBLY
Figure 402. Collective Control Module Assembly
Page 402
Original 67-10-20
2. Cyclic Grip (3). Solder wires to new switch.

A. Cyclic Grip Removal (4). Install screws (2 and/or 6) attaching
switchplate cover (3) and/or handle
(Ref. Figure 403) cover (4).
Power Off Silicone Compound (C221)
(1). Verify all power is removed from (5). Cover screws (2 and/or 6) heads with
aircraft (Ref. Section 96-00-00). silicone compound (C221).
(2). Loosen wire harness collar (1) at base (6). Smooth compound flush with switch
of cyclic grip assembly (2). plate and/or handle.
(3). Remove cyclic grip (2) straight out from D. Cyclic Grip Installation
end of cyclic stick assembly (3).
(Ref. Figure 403)
B. Cyclic Grip Disassemble
Power Off
(Ref. Figure 404)
NOTE: If cyclic grip warranty has expired,
switches may be replaced by owner/opera
tor. (1). Verify all power is removed from
(1). Remove cyclic grip assembly (1) from aircraft (Ref. Section 96-00-00).
cyclic stick. If Auto Pilot or Emergency
CAUTION Floats options are installed,
(2). Remove bonding compound (C221) from
heads of screws (2 and/or 6) of switch change to latest configuration grip (Ref. Fig
plate cover (3) and/or handle cover (4). ure 101, Section 67-10-20).
(3). Remove screws (2 and/or 6) and remove (2). Align connector portion of cyclic grip
switchplate (3) and/or handle (4). assembly (2) with upper end connection
on cyclic stick assembly (3) and plug
(4). Unsolder applicable wires if removing together.
any switches.
(3). Tighten wire harness collar (1).
(5). Remove set screws (5) that secure
specific switches. (4). Restore power to aircraft (Ref. Section
96-00-00).
(6). Remove switch for replacement.
3. Wire Harness W135, Cyclic Controls
C. Cyclic Grip Reassemble
A. Wire Harness W135, Cyclic Controls
(Ref. Figure 404) Removal
(Ref. Figure 403)
(Ref. CSPSPM) Power Off
Item Nomenclature
(1). Install switch for replacement. (1). Verify all power is removed from
(2). Install set screws (5) that secure
specific switches in place. (2). Open access panel R128.
Page 403
67-10-20 Original
(3). Unplug and remove connector (8) at (3). Prepare surface for electrical bond (Ref.
lower end of wire harness - W135 (9) CSP-SPM).
NOTE: Electrical bond preparation should be
(4). Remove cyclic grip assembly (2) Ref. made for outside surface of insert (10) to cy
Section 67-10-20). clic stick assembly (3), and inside surface of
insert (10) to wire harness (9).
NOTE: Cyclic centering strap (13) and washer
(12) are only installed on the pilots cyclic (4). Install cyclic stick insert (10) and wire
stick assembly (3). harness (9) upper connector into cyclic
(5). Remove nut (4), washers (5 and 12), stick (3).
radius blocks (7), cyclic stick centering NOTE: Cyclic centering strap (13) and washer
strap (13) and bolt (6) that secure upper (12) are only installed on the pilots cyclic
end connector of wire harness (9) and stick assembly (3).
cyclic stick insert (10) to cyclic stick (3).
(6). Pull wire harness (9) through cyclic (5). Install cyclic stick centering strap (13),
stick (3) to remove. bolt (6), radius blocks (7), washers (5
and 12) and nut (4).
B. Wire Harness W135, Cyclic Controls
Installation (6). Install cyclic grip assembly (2) Ref.
Section 67-10-20).
(Ref. Figure 403)
(7). Re-attach lower connector (8) onto wire
Power Off harness (9) (Ref Section 98-00-00) and
reattach at lower connection point
under cabin floor.
(8). Ensure bonding jumper assembly (11)
(1). Verify all power is removed from is secure to cyclic stick assembly (3).
(9). Close access panel R128.
(2). Route wire harness - W135 (9) through
cyclic stick assembly (3) from upper end (10). Restore power to aircraft (Ref. Section
to lower end. 96-00-00).
Page 404
Original 67-10-20
REF. 1
REF. 13
10 2
6
1
7
12
13
7
4
REF. 3
3
11
9
8
9G67031A
1. COLLAR 8. LOWER CONNECTOR
2. CYCLIC GRIP ASSEMBLY 9. WIRE HARNESS W135
3. CYCLIC STICK ASSEMBLY 10. INSERT
4. NUT 11. JUMPER ASSEMBLY
6. BOLT 13. CYCLIC STICK CENTERING STRAP
7. RADIUS BLOCK
Figure 403. Cyclic Grip Installation
Page 405
67-10-20 Original
6 (5 PL)
2 (4 PL)
9G67044
1. CYCLIC GRIP ASSEMBLY 4. HANDLE COVER
2. SCREW 5. SET SCREW
3. SWITCHPLATE COVER 6. SCREW
Figure 404. Cyclic Grip Assembly
Page 406
Original 67-10-20
Section
672000
AntiTorque/Directio
nal Flight Controls
ANTITORQUE/DIRECTIONAL FLIGHT CONTROLS

1. Heel Rest Assemblies Sealant, Fuel Resistant (C216)
A. Heel Rest Assemblies Removal
(Ref. Figure 401)
NOTE: Both left and right side heel rest assem (1). Apply sealant (C216) to mating sur
blies are typical. faces of directional control pedal (12)
and pedal shaft assembly (13 or 17).
(1). Remove nuts (1), washers (2), and bolts (2). Install bolt (11), washer (10) and nut (8)
(3) that attach heel rest support (4) to attaching control pedal (12) to shaft
pedals bracket assembly (5). assembly (13 or 17).
(2). Remove screws (6), washers (7) and (3). Torque nut.
nuts (8) from the top of the heel rest
assembly (9). Remove heel rest. 3. Pedal Adjustment Handle
B. Heel Rest Assemblies Installation A. Pedal Adjustment Handle Removal

(Ref. Figure 401)
(Ref. Figure 401)
(1). Remove rivets (14) that attach pedal
(1). Slide heel rest support (4) into place adjustment handle (15) to pedal
and install bolts (3), washers (2), and adjustment pin (16) and remove
nuts (1). handle.
(2). Install screws (6), washers (7) and nuts B. Pedal Adjustment Handle Installation
(8) attaching heel rest assembly (9).
(Ref. Figure 401)
(3). Torque nuts. (1). Position pedal adjustment handle (15)
on pedal adjustment pin (16) and
2. Directional Control Pedals install rivets (14).
A. Directional Control Pedals Removal 4. Pedal Adjustment Pin
(Ref. Figure 401) A. Pedal Adjustment Pin Removal
NOTE: Right and Left sides are typical (Ref. Figure 401)
(1). Remove rivets (14) from pedal adjust
(1). Remove nut (8), washer (10) and bolt ment handle (15).
(11) that attach directional control
pedal (12) to pedal shaft assembly (13 (2). Remove pedal adjustment pin (16).
or 17).
B. Pedal Adjustment Pin Installation
B. Directional Control Pedals Installation (Ref. Figure 401)
(Ref. Figure 401) (1). Install pedal adjustment pin (16).
(2). Position pedal adjustment handle (15)
Consumable Materials on adjustment pin (16) and install
(Ref. CSPSPM) rivets (14).
Item Nomenclature
5. Longitudinal Pivot Bolt
A. Longitudinal Pivot Bolt Removal
Page 401
67-20-00 Original
(Ref. Figure 401)

(1). Remove and discard cotter pin (19). (Ref. CSPSPM)
Remove nut (20), washer (21) and bolt Item Nomenclature
(22) that attach pedal pivot support
(28). C216 Sealant, Fuel Resistant
(2). Remove pedal pivot support (28).

(3). Remove longitudinal pivot bolt (22). NOTE: Prepare area for electrical bond on
shaft assembly where clamp and bonding
B. Longitudinal Pivot Bolt Installation jumper attach (Ref. CSP-SPM).
(Ref. Figure 401)
(1). Install pedal shaft assemblies (13 and
(1). Install longitudinal pivot bolt (22) into 17) while installing pedal pivot support
pedal pivot support (28). (28).
(2). Install washer (21) and nut (20).

(3). Torque nut and install new cotter pin. (20) attaching pedal pivot support (28)
to pedal assembly.
6. Pedal Shaft Assemblies Left and Right
Pilot Pedals (3). Install bolts (26), bushings (25),
A. Pedal Shaft Assemblies Removal washers (24) and nuts (23) attaching
upper ends of pedal return springs (27)
(Ref. Figure 401) to pedal shaft assemblies (13 and 17).
NOTE:
This task is typical to Co-pilot pedal shaft
assemblies.
Position shaft assemblies (17 and 13) in
crank assemblies (18 and 39) respectively,
to minimize tension on pedal return
springs. (4). Install hardware attaching bonding
(1). Remove and discard cotter pin (19). jumper and apply sealant (C216).
(22) that attach pedal pivot support (5). Torque nuts and install new cotter pins.
(28).
(2). Remove and discard cotter pins (19). C. Copilot Pedal Shaft Disengagement
Remove nuts (23), washers (24),
bushings (25) and bolts (26) that attach (Ref. Figure 401)
upper ends of pedal return springs (27)
to directional pedal shaft assemblies
(13 and 17). NOTE: Copilots pedal shaft assemblies can
be temporarily stowed in the full forward
(3). Remove hardware that attaches position.
bonding jumper.
(4). Remove pedal pivot support (28) and (1). Pull up the pedal adjustment handles
remove pedal shaft assemblies (13 and (15).
17).
(2). Pull out the stop adjust knobs (68).
B. Pedal Shaft Assemblies Installation
(Ref. Figure 401) (3). Swing shaft assemblies forward.
Page 402
7. Crank Assembly, Right Pedal Pilot 8. Crank Assembly, Left Pedal Pilot
A. Crank Assembly (Left Pedal) Removal
A. Crank Assembly (Right Pedal) Removal
(Ref. Figure 401)
(Ref. Figure 401) NOTE: Position shaft assembly (13) in crank
assembly (39) to minimize tension on pedal
NOTE: Position shaft assembly (17) in crank return spring (27).
assembly (18) to minimize tension on pedal
return spring (27).
Remove nut (23), washers (24), bushing
(25) and bolt (26) that attach upper end
(1). Remove and discard cotter pin (19). of pedal return spring (27) to direction
Remove nut (23), washers (24), bushing al pedal shaft assembly (13).
(25) and bolt (26) that attach upper end
of pedal return spring (27) to direction (2). Remove and discard cotter pin (19).
al pedal shaft assembly (17). Remove nut (20) washers (29) and bolt
(30) that attach directional link
(2). Remove and discard cotter pin (19). assembly (31) to crank assembly (39).
Remove nut (20) washers (29) and bolt (3). Remove nut (32), washers (29 and 33),
(30) that attach directional link friction retainer (34), compression
assembly (31) to crank assembly (18). spring (35) friction disks (36) and bolt
(37) that attach friction links (38) to
(3). Remove and discard cotter pin (19). crank assembly (39).
(28).
(28).
(4). Slide pivot support (28) out of pedal
assembly. (5). Slide pivot support (28) out of pedal
assembly.
(5). Raise pedal adjustment handle (15) and (6). Raise pedal adjustment handle (15) and
remove crank assembly (18). remove crank assembly (39).
B. Crank Assembly (Left Pedal) Installation
B. Crank Assembly, (Right Pedal)
Installation (Ref. Figure 401)
(1). Position crank assembly (39) and
(Ref. Figure 401) install pedal pivot support (28).
(1). Position crank assembly (18) and (2). Install bolt (22), washer (21) and nut
install pedal pivot support (28). (20) attaching pedal pivot support (28).
(3). Install bolt (37), friction disks (36),
(2). Install bolt (22), washer (21) and nut compression spring (35), friction
(20) attaching pedal pivot support (28). retainer (34), washers (29 and 33) and
nut (32) attaching friction links (38) to
(3). Install bolt (30), washers (29) and nut crank assembly (39).
(20) attaching link assembly (31) to (4). Install bolt (30), washers (29) and nut
crank assembly (18). (20) attaching link assembly (31) to
(4). Install bolt (26), bushing (25), washers
(24) and nut (23) attaching upper end of (5). Install bolt (26), bushing (25), washers
pedal return spring (27) to directional (24) and nut (23) attaching upper end of
pedal shaft assembly (17). pedal return spring (27) to directional
pedal shaft assembly (13).
Page 403
67-20-00 Original
9. Pedal Pivot Support 11. Pedal Spring Support

A. Pedal Spring Support Removal
A. Pedal Pivot Support Removal
(Ref. Figure 401)
(Ref. Figure 401)
(1). Remove rivets (14) from adjustment
handle (15) and remove handle.
(1). Remove right side chin windscreen to
gain access to directional pedal assem (2). Remove adjustment pin (16), pedal
bly area (Ref. Section 53-10-00). spring (40) and spring support (41).
(2). Remove and discard cotter pin (19). B. Pedal Spring Support Installation
Remove nut (20), washer (21) and bolt (Ref. Figure 401)
(28). (1). Install pedal spring (40), spring support
(41) and adjustment pin (16).
(3). Remove pedal pivot support (28) from (2). Install adjustment handle (15) with
pedal assembly. rivets (14).
B. Pedal Pivot Support Installation 12. Spring Return Arbor

A. Spring Return Arbor Removal
(Ref. Figure 401)
(Ref. Figure 401)
(1). Install pedal pivot support (28) into (1). Remove nuts (42), washers (24 and 43)
pedal assembly. and screws (44) that attach lower ends
of return springs (27) to crank assem
(2). Install bolt (22), washer (21) and nut blies (18 or 39).
(20) attaching pedal pivot support.
(3). Torque nut and install new cotter pin. Remove nuts (23), washers (24),
(4). Install right side chin windscreen (Ref. upper ends of pedal return springs (27)
Section 53-10-00). to pedal shaft assemblies (13 or 17).
10. Pedal Spring Remove nuts (23), washers (24) and
bolts (45) that attach spring return
A. Pedal Spring Removal arbors (46) to crank assemblies (18 or
39).
(Ref. Figure 401)
B. Spring Return Arbor Installation
(1). Remove rivets (14) from adjustment (Ref. Figure 401)
handle (15) and remove.
(23) attaching spring return arbors (46)
(2). Remove adjustment pin (16), pedal
to crank assemblies (18 or 39).
spring (40) and spring support (41).
(2). Install screws (44), washers (24 and 43)
B. Pedal Spring Installation and nuts (42) attaching lower ends of
return springs (27) to crank assemblies
(Ref. Figure 401) (18 or 39).
(3). Install bolts (26), bushings (25),
(1). Install pedal spring (40), spring support
washers (24) and nuts (23) attaching
(41) and adjustment pin (16).
upper ends of return springs (27) to
pedal shaft assemblies (13 or 17).
(2). Install adjustment handle (15) with
rivets (14). (4). Torque nuts and install new cotter pins.
Page 404
Original 67-20-00
13. Pedal Return Springs 14. FS 104.459 Lower Directional Crank

Assembly
A. Pedal Return Springs Removal A. Lower Directional Crank Assembly
Removal
NOTE: Left and Right side springs are typical.
(Ref. Figure 401)
(Ref. Figure 401) (1). Remove and discard cotter pins (19).
Remove nuts (20), washers (29) and
bolts (30) that attach both left and
(1). Remove nuts (42), washers (24 and 43) right side link assemblies (31) to lower
and screws (44) that attach lower ends directional crank assembly (48).
of pedal return springs (27) to crank
assemblies (18 or 39). (2). Remove and discard cotter pin (19).
(2). Remove and discard cotter pins (19). (47) that attach crank assembly (48) to
Remove nuts (23), washers (24), pedals bracket assembly (5).
bushings (25) and bolts (26) that attach B. Lower Directional Crank Assembly
upper ends of return springs (27) to Installation
pedal shaft assemblies (13 or 17).
(Ref. Figure 401)
(3). Remove and discard cotter pins (19). (1). Install bolt (47), washers (29) and nut
Remove nuts (23), washers (24) and (20) attaching lower directional crank
bolts (45) that attach spring return assembly (48) to pedals bracket
arbors (46) to crank assemblies (18 or assembly (5).
39).
(4). Remove pedal return spring (27). (20) attaching both left and right side
link assemblies (31) to crank assembly
(48).
B. Pedal Return Springs Installation
(3). Torque nuts and install new cotter pin.
(Ref. Figure 401) 15. Directional Pedal Link Assembly
(1). Install pedal return spring (27) around A. Directional Pedal Link Assembly
spring return arbors (46). Removal
(Ref. Figure 401)
(23) attaching spring return arbors (46) (1). Remove and discard cotter pins (19).
to crank assemblies (18 or 39). Remove nuts (20), washers (29) and
bolts (30) that attach both upper and
lower ends of link assemblies (31).
(3). Install screws (44), washers (24 and 43)
and nuts (42) attaching the lower ends (2). Remove link assembly (31).
of return springs (27) to crank assem
blies (18 or 39). B. Directional Pedal Link Assembly
Installation
(4). Install bolts (26), bushings (25), (Ref. Figure 401)
washers (24) and nuts (23) attaching
upper ends of return springs (27) to (1). Install bolts (30), washers (29) and nuts
pedal shaft assemblies (13 or 17). (20) attaching both upper and lower
ends of link assemblies (31).
Page 405
67-20-00 Original
16. Friction Disk B. Friction Link Installation
A. Friction Disk Removal (Ref. Figure 401)
(Ref. Figure 401) (1). Install bolt (30), bushing (51), washers
(49 and 50) and nut (20) attaching
(1). Remove nut (32), washers (29 and 33), friction links (38) to pedals bracket
bolt (37), compression spring (35), assembly (5).
friction retainer (34) and friction disks
(36). (2). Install bolt (37), friction disks (36),
friction retainer (34), compression
B. Friction Disk Installation spring (35), washers (29 and 33) and
nut (32) attaching lower end of friction
(Ref. Figure 401) links (38).
(1). Install bolt (37), friction disks (36), 19. Directional Interconnect Control Rod
friction retainer (34), compression Assembly
spring (35), washers (29 and 33) and
nut (32). Torque nut. A. Directional Interconnect Control Rod
Assembly Removal
17. Friction Adjusting Retainer
(Ref. Figure 401)
A. Friction Adjusting Retainer Removal
(1). Remove either right or left side chin
(Ref. Figure 401) windscreen to gain access to directional
pedal assembly area (Ref. Section
(1). Remove nut (32), washers (29 and 33), 53-10-00).
bolt (37), compression spring (35) and
friction adjusting retainer (34). (2). Remove and discard cotter pins (19).
Remove nuts (20), washers (29 and 50)
B. Friction Adjusting Retainer Installation and bolts (55) that attach directional
interconnect control rod assembly (64)
(Ref. Figure 401) to pilots lower directional crank
assembly (48) and co-pilots lower crank
(1). Install bolt (37), friction adjusting
assembly (65).
retainer (34), compression spring (35),
washers (29 and 33) and nut (32). (3). Remove interconnect control rod (64).
Torque nut.
B. Directional Interconnect Control Rod
18. Friction Link Assembly Installation
A. Friction Link Removal (Ref. Figure 401)
(Ref. Figure 401) (1). Install bolts (55), washers (29 and 50)
and nuts (20) attaching directional
(1). Remove nut (32), washers (29 and 33), interconnect control rod assembly (64)
bolt (37), compression spring (35), to pilots lower directional crank
friction retainer (34) and friction disks assembly (48) and co-pilots lower crank
(36). assembly (65).
(2). Remove and discard cotter pins (19). (2). Verify directional control system
Remove nut (20), washers (49 and 50), rigging. (Ref. Section 67-20-00)
bushing (51) and bolt (30) that attach
friction links (38) to pedals bracket (3). Torque nuts and install new cotter pins.
assembly (5).
(4). Install right or left side chin windscreen
(3). Remove friction links (38). (Ref. Section 53-10-00).
Page 406
Original 67-20-00
20. Directional Crank Assembly (FS 109.000) 21. Pedal Directional Control Clevis
Assembly
A. Directional Crank Assembly Removal
(Ref. Figure 401) A. Pedal Directional Control Clevis
Assembly Removal
(1). Open access panel R128 (Ref. Section
06-00-00).
(Ref. Figure 401)
and bolt (53) that attach Fwd cockpit (1). Open access panel R128 (Ref. Section
directional control rod assembly (59) to 06-00-00).
FS 109.000 directional crank assembly
(58).
(3). Remove and discard cotter pin (19). Remove nut (20), washers (29 and 50),
Remove nut (20), washers (50 and 52), and bolt (54) that attach FS 109.000
and bolt (53) that attach Aft cockpit directional crank assembly (58) to pedal
directional control rod assembly (57) to directional control clevis assembly (60).
(4). Remove and discard cotter pin (19). (3). Remove nuts (67), washers (50), and
Remove nut (20), washers (29 and 50), bolts (66) that attach pedal directional
and bolt (54) that attach crank assem control clevis assembly (60) to bulk
bly (58) to pedal directional control head.
clevis assembly (60).
(4). Remove pedal directional control clevis
(5). Remove directional crank assembly (58) assembly (60).
B. Directional Crank Assembly Installation
(Ref. Figure 401) B. Pedal Directional Control Clevis
(1). Install bolt (54), washers (29 and 50),
and nut (20) attaching FS 109.000 (Ref. Figure 401)
directional crank assembly (58) to pedal
directional control clevis assembly (60).
NOTE: Adjustment of control rod might be re (67) attaching pedal directional control
quired for installation. clevis assembly (60) to bulkhead.
(2). Install bolt (53), washers (50 and 52)
and nut (20) attaching aft cockpit (2). Install bolt (54), washers (29 and 50)
directional control rod assembly (57) to and nut (20) attaching FS 109.000
crank assembly (58). directional crank assembly (58) to pedal
directional control clevis assembly (60).
and nut (20) attaching Fwd cockpit
directional control rod assembly (59) to (3). Verify directional control system rigging
crank assembly (58). (Ref. Section 67-20-00).
(4). Verify directional control system rigging
(Ref. Section 67-20-00). (4). Torque all nuts and install new cotter
pins.
(6). Close access panel R128 (Ref. Section (5). Close access panel R128 (Ref. Section
06-00-00). 06-00-00).
Page 407
67-20-00 Original
22. Forward Cockpit Directional Control Rod 23. Aft Cockpit Directional Control Rod
Assembly Assembly
A. Forward Cockpit Directional Control Rod A. Aft Cockpit Directional Control Rod
Assembly Removal Assembly Removal
(1). Remove pilot crew seat (Ref. Section (1). Remove pilot crew seat (Ref. Section
25-10-00). 25-10-00).
(2). Remove floor panel AR138 (Ref. Section

(2). Remove floor access panel AR138 (Ref.
53-20-00).
Section 53-20-00).
Remove nut (20), washers (50 and 52) and bolt (53) that attach Aft cockpit
and bolt (53) that attach forward directional control rod assembly (57) to
cockpit directional control rod assembly FS 109.000 directional crank assembly
(59) to FS 109.000 directional crank (58).
assembly (58).
Remove nut (20), washers (50 and 52) and bolt (55) that attach control rod
and bolt (55) that attach control rod assembly (57) to lower closet bellcrank
assembly (59) to pedal crank assembly assembly (61).
(18).
(5). Remove control rod assembly (57).
(5). Remove control rod assembly (59).
B. Aft Cockpit Directional Control Rod
B. Forward Cockpit Directional Control Rod Assembly Installation
(Ref. Figure 401)
(Ref. Figure 401)
(1). Install bolt (53), washers (50 and 52) quired for installation.
and nut (20) attaching forward cockpit
directional control rod assembly (59) to (1). Install bolt (55), washers (50 and 52)
FS 109.000 directional crank assembly and nut (20) attaching Aft cockpit
(58). directional control rod assembly (57) to
lower closet bellcrank assembly (61).
and nut (20) attaching control rod
and nut (20) attaching control rod
assembly (59) to pedal crank assembly
assembly (57) to FS 109.000 directional
(18).
(3). Verify directional control system (3). Verify directional control system
rigging. (Ref. Section 67-20-00) rigging. (Ref. Section 67-20-00)
(5). Install floor access panel AR138 (Ref. (5). Install floor access panel AR138 (Ref.
Section 53-20-00). Section 53-20-00).
(6). Install pilot crew seat (Ref. Section (6). Install pilot crew seat (Ref. Section
25-10-00). 25-10-00).
Page 408
Original 67-20-00
24. Directional Lower Closet Bellcrank (3). Install bolt (56), washers (50 and 52),
Assembly and nut (20) attaching closet control
rod assembly (63) to lower closet
A. Lower Closet Bellcrank Assembly bellcrank assembly (61).
Removal
(4). Verify directional control system
(Ref. Figure 401)
rigging. (Ref. Section 67-20-00)
25-10-00). (5). Torque nuts and install new cotter pins.
(2). Remove floor access panel AR138 (Ref. (6). Install controls closet panel behind
Section 53-20-00). right crew seat (Ref. Section 25-10-00).
(3). Remove insulation panels behind right (7). Install insulation panels behind right
crew seat (Ref. Section 25-10-00). crew seat (Ref. Section 25-10-00).
(4). Remove controls closet panel behind (8). Install floor access panel AR138 (Ref.
right crew seat (Ref. Section 25-10-00). Section 53-20-00).
Remove nut (20), washers (50 and 52), (9). Install pilot crew seat (Ref. Section
and bolt (55) that attach Aft cockpit 25-10-00).
directional control rod assembly (57) to
lower closet bellcrank assembly (61). 25. Directional Closet Control Rod Assembly
(6). Remove and discard cotter pin (19). A. Directional Closet Control Rod Assembly
Remove nut (20), washers (50 and 52) Removal
and bolt (56) that attach closet control
rod assembly (63) to bellcrank assembly (Ref. Figure 401)
(61).
25-10-00).
(62) that attach lower closet bellcrank
assembly (61) to lower closet bracket (2). Remove floor access panel AR138 (Ref.
assembly. Section 53-20-00).
(8). Remove directional lower closet (3). Remove insulation panels behind right
bellcrank assembly (61). crew seat (Ref. Section 25-10-00).
B. Directional Lower Closet Bellcrank (4). Remove controls closet panel behind
Assembly Installation right crew seat (Ref. Section 25-10-00).
(Ref. Figure 401) (5). Remove and discard cotter pin (19).
Remove nut (20), washers (50 and 52),
(1). Install bolt (62), washers (29), and nut
and bolt (56) that attach closet control
(20) attaching lower closet bellcrank
rod assembly (63) to lower closet
assembly (61) to lower closet bracket
assembly.
NOTE: Adjustment of control rods might be re (6). Remove and discard cotter pin (19).
quired for installation. Remove nut (20), washers (50), and bolt
(56) that attach closet control rod
(2). Install bolt (55), washers (50 and 52), assembly (63) to upper closet direction
and nut (20) attaching Aft cockpit al bellcrank assembly.
directional control rod assembly (57) to
lower closet bellcrank assembly (61). (7). Remove control rod (63).
Page 409
67-20-00 Original
B. Directional Closet Control Rod Assembly (4). Remove pedal pivot support (28), pedal
Installation shaft assemblies (13 and 17) and pedal
crank assemblies (18 and 39) (Ref.
NOTE: Adjustment of control rods might be re (5). Remove attaching hardware that
quired for installation. secures directional pedal bracket
assembly (5) to airframe structure.
(1). Install bolt (56), washers (50), and nut
(20) attaching closet control rod
assembly (63) to upper closet bellcrank B. Directional Pedals Bracket Assembly
assembly. Installation
(2). Install bolt (56), washers (50 and 52), (Ref. Figure 401)
and nut (20) attaching closet control
rod assembly (63) to lower closet Consumable Materials
bellcrank assembly (61). (Ref. CSPSPM)
Item Nomenclature
(3). Verify directional control system
rigging. (Ref. Section 67-20-00) C216 Sealant, Fuel Resistant
(4). Torque nuts and install new cotter pins. (1). Prepare surface for electrical bond (Ref.
CSP-SPM).
(5). Install controls closet panel behind
right crew seat (Ref. Section 25-10-00). (2). Align directional pedal bracket assem
bly (5) with airframe structure and
(6). Install insulation panels behind right secure with attaching hardware.
crew seat (Ref. Section 25-10-00). Torque nuts.
(7). Install floor access panel AR138 (Ref. Sealant, Fuel Resistant (C216)
Section 53-20-00).

25-10-00).
(3). Seal top of bracket assembly (5) to
26. Directional Pedals Bracket Assembly airframe mating structure using
sealant (C216) (Ref. CSP-SPM).
A. Directional Pedals Bracket Assembly
Removal (4). Install pedal crank assemblies (18 and
39), pedal shaft assemblies (13 and 17)
(Ref. Figure 401) and pedal pivot support (28) (Ref.
Section 67-20-00).
(1). Remove directional pedal link assem
blies (31) (Ref. Section 67-20-00). (5). Install pedal friction device components
- friction links (38), friction disks (36),
(2). Remove lower directional crank compression spring (35), friction
assembly (48) (Ref. Section 67-20-00). retainer (34) (Ref. Section 67-20-00).
(6). Install lower directional crank assem
(3). Remove friction device components - bly (48) (Ref. Section 67-20-00).
friction retainer (34), compression
spring (35), friction disks (36), friction (7). Install directional pedal link assemblies
links (38) (Ref. Section 67-20-00). (31) (Ref. Section 67-20-00).
Page 410
Original 67-20-00
27. Pedal Anticipator Assembly (1). Align hole in arm with hole in bracket
Potentiometer (Transducer) (902 CONFIG) and install potentiometer. Tighten nut
sufficiently to prevent movement.
A. Potentiometer Removal
(2). Connect electrical wires to potentiome
(Ref. Figure 401) ter (Ref. CSP-SPM).
(1). Tag wires connected to potentiometer (3). Do the pedal anticipator rigging.
(69) for reference during installation.
28. Bracket, Potentiometer Pedal
Anticipator (902 CONFIG)
(2). Disconnect electrical wires from
potentiometer (69) (Ref. CSP-SPM). A. Potentiometer Bracket Removal
(3). Remove cotter pin (71) from bolt (81). (1). Remove potentiometer.
(4). Loosen nut (79) sufficiently to remove (2). Remove cotter pins (71), nuts (79),
potentiometer (69).Remove potentiome washers (80), and bolts (83). Remove
ter. bracket (77).
B. Potentiometer Bracket Installation
B. Potentiometer Installation
(1). Install bracket, bolts, washers, and
(Ref. Figure 401) nuts. Torque nuts and install new
cotter pins
NOTE: Make sure you push potentiometer fully
against bracket before you tighten nut. (2). Install potentiometer.
Page 411
17
10
8
12 13
12
11
10
8
15 14
22
28 11
16
5
40
21 20 19
41 39
50 20
19 18 46
23 55
24
19
24
26 48 29
24 64
42 68
25
24 24
50 20
55
30 45
29 19 19
27
19 23
44
43 39 29
31 65
29 20 17 29
19 30
19 50
20
51
29 20
19
29 29
29 37 30 38
20 49
30 19 49
38
48 50
20
29 19
29 33
29 30 36
47
48 36 32
31
5
34 35 29
9G670291C
Figure 401. AntiTorque/Directional Pedal Assembly (Sheet 1 of 2)
Page 412
Original 67-20-00
81
80
82
78 80
71 80
79
71
77
79 16 80 71
80 83
73 6
6 9
76 3 9
74 52
69 4 20
75 72
72
70 19
2 50 4
1 66
72 80 71 67
72
79 54 REF. 18
48 7 50
50
902 CONFIG 58 29
8 20
53 55
19
7 59
50 60
8
20 29 29 52
62 53
19
20
50
19
52
57 20
56 19
50 2x
20
19
63
61
56 50 19
VIEW ROTATED
LOOKING FORWARD
20
52 19
55 20 52
50
9G670292A
Figure 401. AntiTorque/Directional Pedal Assembly (Sheet 2 of 2)
Page 413
67-20-00 Original

1. NUT 43. WASHER
2. WASHER 44. SCREW
3. BOLT 45. BOLT
4. HEEL REST SUPPORT 46. SPRING RETURN ARBOR
5. PEDAL BRACKET ASSEMBLY 47. BOLT
6. SCREW 48. LOWER DIRECTIONAL CRANK ASSEMBLY
8. NUT 50. WASHER
9. HEEL REST ASSEMBLY 51. BUSHING
11. BOLT 53. BOLT
12. CONTROL PEDAL 54. BOLT
13. LEFT PEDAL SHAFT ASSEMBLY 55. BOLT
14. RIVET 56. BOLT
15. PEDAL ADJUSTMENT HANDLE 57. AFT COCKPIT DIRECTIONAL CONTROL ROD
16. PEDAL ADJUSTMENT PIN 58. FS 109.000 DIRECTIONAL CRANK ASSEMBLY
17. RIGHT PEDAL SHAFT ASSEMBLY
59. FORWARD COCKPIT DIRECTIONAL CONTROL ROD
18. PEDAL CRANK ASSEMBLY, RIGHT
60. PEDAL DIRECTIONAL CONTROL CLEVIS ASSEMBLY
19. COTTER PIN
61. LOWER CLOSET BELLCRANK ASSEMBLY
20. NUT
62. BOLT
21. WASHER
63. CLOSET CONTROL ROD ASSEMBLY
22. BOLT, LONGITUDINAL PIVOT
64. DIRECTIONAL INTERCONNECT CONTROL ROD
23. NUT
65. COPILOTS DIRECTIONAL LOWER CRANK ASSEMBLY
24. WASHER
66. BOLT
25. BUSHING
67. NUT
26. BOLT
27. PEDAL RETURN SPRING 68. STOP ADJUST KNOB
28. PEDAL PIVOT SUPPORT 69. POTENTIOMETER (TRANSDUCER)
29. WASHER 70. BOLT
31. LINK ASSEMBLY 72. WASHER
32. NUT 73. NUT
33. WASHER 74. SPACER
34. FRICTION RETAINER 75. BUSHING
35. COMPRESSION SPRING 76. LINK
36. FRICTION DISK 77. BRACKET
37. BOLT 78. ARM
38. FRICTION LINK 79. NUT
39. PEDAL CRANK ASSEMBLY, LEFT 80. WASHER
40. PEDAL SPRING 81. BOLT
41. SPRING SUPPORT 82. BOLT
42. NUT 83. BOLT
Page 414
Original 67-20-00
29. Directional Upper Closet Bellcrank (6). Install roof panels (Ref. Section
Assembly 25-20-00).
A. Directional Upper Closet Bellcrank (7). Close access panels T155 and R155
Assembly Removal (Ref. Section 53-30-00).
(Ref. Figure 402)
30. Directional Actuator Input Control Rod
(1). Remove access panels T155 and R155 Assembly
A. Directional Actuator Input Control Rod
(2). Remove roof panels (Ref. Section Assembly Removal
25-20-00).
(Ref. Figure 402)
(3). Remove FS 155.500 FOD cover (1) (Ref.
Section 67-10-00). (1). Remove roof panels (Ref. Section
25-20-00).
Remove nuts (3), washers (4), and bolts (2). Remove and discard cotter pin (2).
(5) that attach closet control rod Remove nut (3), washers (4), and bolt
assembly (63, Ref. Figure 401) and (5) that attach directional actuator
directional actuator input control rod input control rod assembly (6) to
assembly (6) to directional upper closet directional upper closet bellcrank
bellcrank assembly (7). assembly (7).
(5). Remove and discard cotter pin (2). (3). Remove and discard cotter pin (2).
Remove nuts (3), washers (4), and bolt Remove nut (3) and washer (10) that
(8) that attach bellcrank assembly (7) attach control rod assembly (6) to
to control deck bracket assembly (9). directional actuator (11).
(6). Remove bellcrank assembly (7). (4). Remove control rod assembly (6).
B. Directional Upper Closet Bellcrank B. Directional Actuator Input Control Rod
Assembly Installation Assembly Installation
(1). Install bolt (8), washers (4), and nuts
(3) attaching directional upper closet quired for installation.
bellcrank assembly (7) to control deck
bracket assembly (9). (1). Install washers (10) and nut (3)
NOTE: Adjustment of control rods might be re attaching directional actuator input
quired for installation. control rod assembly (6) to directional
actuator (11).
(2). Install bolts (5), washers (4), and nuts
(3) attaching directional actuator input (2). Install bolt (5), washers (4), and nut (3)
control rod assembly (6) and closet attaching control rod assembly (6) to
control rod assembly (63, Ref. directional upper closet bellcrank
Figure 401) to bellcrank assembly (7). assembly (7).
(3). Verify directional control system (3). Verify directional control system rigging
rigging. (Ref. Section 67-20-00) (Ref. Section 67-20-00).
(5). Install FS 155.500 FOD cover (1) (Ref. (5). Install roof panels (Ref. Section
Section 67-10-00). 25-20-00).
Page 415
67-20-00 Original
31. Directional Actuator Output Control Rod 32. Hydraulic AntiTorque/Directional

Assembly Actuator
A. Directional Actuator Output Control Rod A. AntiTorque/Directional Actuator
Assembly Removal Removal
(1). Remove roof panels (Ref. Section (1). Remove roof panels (Ref. Section
25-20-00). 25-20-00).
(2). Remove and discard cotter pin (2). (2). Remove pressure from hydraulic
Remove nut (3) washers (4) and bolt system (Ref. Section 29-00-00).
(13) that attach directional actuator (3). Disconnect hydraulic lines from
output control rod assembly (12) to directional actuator (11) (Ref. Section
splitter assembly (14). 29-00-00).
(3). Remove and discard lockwire. Remove (4). Remove actuator input control rod
jam nut (15) and lockwasher (16) that assembly (6) (Ref. Section 67-20-00).
attach control rod assembly (12) to
directional actuator (11). (5). Remove actuator output control rod
assembly (12) (Ref. Section 67-20-00).
(4). Remove control rod (12).
B. Directional Actuator Output Control Rod Remove nut (3), washer (4) and bolt
Assembly Installation (17) that attach actuator (11) to
actuator attach bracket assembly (18).
(Ref. Figure 402)
Consumable Materials that attach anti-rotation actuator
(Ref. CSPSPM) bracket (20) and remove actuator (11).
Item Nomenclature B. AntiTorque/Directional Actuator
C702 Lockwire Installation
(Ref. Figure 402)
quired for installation. Consumable Materials
(1). Hand tighten cap of directional actua (Ref. CSPSPM)
tor output control rod assembly (12) Item Nomenclature
until it bottoms out onto stud of C702 Lockwire
directional actuator (11). Install
lockwasher (16) and jam nut (15).
(1). Install anti-torque/directional actuator
(2). Install bolt (13), washers (4) and nut (3) (11) while installing anti-rotation
attaching control rod assembly (12) to actuator bracket (20) and attach with
splitter assembly (14). washers (10) and bolts (19). Torque
bolts.
(Ref. Section 67-20-00). (2). Install bolt (17), washer (4) and nut (3)
attaching actuator (11) to actuator
(4). Torque jam nut and safety with attach bracket assembly (18). Torque
lockwire (C702) for step 1. nut and install new cotter pin.
(5). Torque nut and install new cotter pin (3). Install actuator output control rod
for step 2. assembly (12, Ref. Section 67-20-00).
(6). Install roof panels (Ref. Section (4). Install actuator input control rod
25-20-00). assembly (6) (Ref. Section 67-20-00).
Page 416
Original 67-20-00
(5). Attach hydraulic lines to actuators (Ref. B. AntiRotation Actuator Bracket

Section 29-00-00). Installation
(Ref. Figure 402)
(6). Safety hydraulic line connections using
lockwire (C702). (1). Install bolts (19) and washers (10)
attaching anti-rotation actuator
(7). Restore pressure to hydraulic system bracket (20) and actuator attach
(Ref. Section 29-00-00). bracket assembly (18) to mounting
surface. Torque bolts.
(8). Service hydraulic system (Ref. Section (2). Install roof panels (Ref. Section
29-00-00). 25-20-00).
(9). Verify no leaks are present in flam 34. Actuator Attach Bracket Assembly
ance or replacement of components, A. Actuator Attach Bracket Assembly
lines, or fittings has occurred, by Removal
application of system pressure and (Ref. Figure 402)
being returned to service. (1). Remove roof panels (Ref. Section
25-20-00).
(10). If actuator was removed for access only
and no adjustments were made to the
actuator or attaching controls, perform
(17) that attach directional actuator
Anti-Torque/Directional Controls
(11) to actuator attach bracket assem
Travel Verification (Ref Section
bly (18).
67-20-00).
(11). If actuator is being replaced with a new that attach anti-rotation actuator
or repaired unit, the directional controls bracket (20) and one side of actuator
must be rigged (Ref. Section 67-20-00 attach bracket assembly (18) to
- Anti-Torque / Directional Control mounting surface.
System Rigging).
that attach other side of attach bracket
assembly (18) to mounting surface.
25-20-00).
33. AntiRotation Actuator Bracket that attach bracket assembly (18) and
interior light support clip assembly (24)
to mounting surface.
A. AntiRotation Actuator Bracket Removal
(Ref. Figure 402)
B. Actuator Attach Bracket Assembly
Installation
25-20-00). (Ref. Figure 402)
attaching bracket assembly (18) and
that attach anti-rotation actuator
interior light support clip assembly (24)
bracket (20) and actuator attach
to mounting surface.
bracket assembly (18) to mounting
surface. (2). Install bolts (19) and washers (10)
attaching anti-rotation actuator
(3). Remove bracket (20). bracket (20) and one side of actuator
Page 417
67-20-00 Original
attach bracket assembly (18) to mounting surface, and bolts (19) and
mounting surface. washers (4, 23 and 29) to vertical
mounting surface. Torque bolts.
attaching other side of attach bracket (2). Connect force limiting control rod
assembly (18) to mounting surface. assembly (26) (Ref. Section 67-20-00)
Torque all bolts. to splitter cam (28).
(4). Install bolt (17), washer (4) and nut (3), (3). Connect FS 231.500 directional control
attaching directional actuator (11) to rod assembly (25) (Ref. Section
actuator attach bracket assembly (18). 67-20-00) to splitter assembly (14).
(5). Verify directional control system rigging (4). Connect actuator output control rod
(Ref. Section 67-20-00). assembly (12) (Ref. Section 67-20-00)
to splitter assembly (14).
(7). Install roof panels (Ref. Section (Ref. Section 67-20-00).
25-20-00).
(6). Secure baggage compartment soft
35. Splitter Assembly insulation roof panels (Ref. Section
25-50-00).
A. Splitter Assembly Removal
36. Splitter Cam
(Ref. Figure 402)
A. Splitter Cam Removal
(1). Gain access to splitter assembly (14)
through baggage compartment soft (Ref. Figure 402)
25-50-00).
through baggage compartment soft
(2). Disconnect actuator output control rod insulation roof panels (Ref. Section
assembly (12) Ref. Section 67-20-00) 25-50-00).
from splitter assembly (14). (2). Disconnect force limiting control rod
(3). Disconnect FS 231.500 directional assembly (26) Ref. Section 67-20-00)
control rod assembly (25) Ref. Section from splitter cam (28).
67-20-00) from splitter assembly (14). (3). Disconnect lateral control rod assembly
(33, Ref. Section 67-20-00) from
(4). Disconnect force limiting control rod
splitter cam (28).
assembly (26) and lateral control rod
assembly (33) Ref. Section 67-20-00) (4). Remove bolts (30) and washers (31 and
from splitter cam (28). 32) that attach splitter cam (28) to
splitter assembly (14).
attach splitter assembly (14) to roof (5). Remove splitter cam (28).
mounting surface, and bolts (19) and
washers (4, 23 and 29) from vertical B. Splitter Cam Installation
mounting surface.
(Ref. Figure 402)
(6). Remove splitter assembly (14).
(1). Install bolts (30) and washers (31 and
B. Splitter Assembly Installation 32) attaching splitter cam (28) to
splitter assembly (14). Torque bolts.
(Ref. Figure 402)
(2). Connect force limiting control rod
(1). Install bolts (27) and washers (4) assembly (26) Ref. Section 67-20-00) to
attaching splitter assembly (14) to roof splitter cam (28).
Page 418
Original 67-20-00
(3). Connect lateral control rod assembly 38. Lateral Control Rod Assembly
(33) Ref. Section 67-20-00) to splitter
cam (28). A. Lateral Control Rod Assembly Removal
(4). Verify directional control system rigging (Ref. Figure 402)

(5). Secure baggage compartment soft (Ref. Section 67-20-00).
25-50-00). (2). Remove and discard cotter pin (2).
37. FS 231.500 Control Rod Assembly (37) that attach lateral control rod
assembly (33) to splitter assembly (14).
A. FS 231.500 Control Rod Assembly
Removal (3). Remove and discard cotter pin (2).
Remove nut (3), washers (4 and 34),
(Ref. Figure 402) track rollers (35) and bolt (36) that
attach lateral control rod (33) and force
(1). Gain access to FS 231.500 control rod
limiting control rod assembly (26) to
assembly (25) through baggage
splitter cam (28).
compartment soft insulation roof panels
(Ref. Section 25-50-00). (4). Remove lateral control rod (33).
(2). Remove and discard cotter pins (2). B. Lateral Control Rod Assembly
Remove nuts (3), washers (4) and bolts Installation
(13) that attach both ends of FS
231.500 control rod assembly (25). (Ref. Figure 402)
(3). Remove control rod assembly (25). NOTE: Install washers (4 or 23) in any com
bination necessary to establish required
B. FS 231.500 Control Rod Assembly gap.
Installation
(1). Install bolt (36), track rollers (35),
(Ref. Figure 402)
washers (4 and 34) and nut (3) attach
(1). Install bolts (13), washers (4) and nuts ing lateral control rod assembly (33)
(3) attaching both ends of FS 231.500 and force limiting control rod assembly
control rod assembly (25). (26) to splitter cam (28).
(2). Verify directional control system rigging (2). Install bolt (37), washers (4) and nut (3)
(Ref. Section 67-20-00). attaching lateral control rod (33) to
splitter assembly (14).
(4). Secure baggage compartment soft (Ref. Section 67-20-00).
25-50-00). (4). Torque nuts and install new cotter pins.
Page 419
67-20-00 Original
39. Force Limiting Control Rod Assembly (2). Install bolt (38), washers (4) and nut (3)
to secure control rod (26) to outer
A. Force Limiting Control Rod Assembly bellcrank assembly (39).
Removal
(Ref. Figure 402) (Ref. Section 67-20-00).
(1). Remove tailboom, (Ref. Section (4). Torque nuts (3 and 61).
53-40-00).
(5). Install new cotter pin (2), and safety
(2). Remove diverter plate and aft diffuser lock washer (62) using lockwire (C702).
(6). Apply torque stripe (Ref. CSP-SPM,
(3). Lower hinged avionics shelf containing Section 20-10-00, Identification
right hand electronic engine control Stripe).
(EEC) (Ref. Section 25-70-00).
40. FS 234.000 Directional Bellcrank
(4). Detach electrical connectors from EEC Assembly
(Ref. Section 76-00-00), and stow away
from work area. A. Directional Bellcrank Assembly Removal
Make sure attached rod end (Ref. Figure 402)

CAUTION does not twist. Damage to the (1). Gain access to directional bellcrank
rod end bearing can occur. assembly (40) through baggage
(5). Remove nut (3), washers (4) and bolt compartment soft insulation roof panels
(38) that attach force limiting control (Ref. Section 25-50-00).
rod (26) to outer bellcrank assembly (2). Remove and discard cotter pins (2).
(39). Remove nuts (3), washers (4) and bolts
(13) that attach FS 231.500 control rod
(6). Unthread control rod (26) from rod end
assembly (25) and FS 234.000 direc
(60) attached to lateral control rod (33)
tional control rod assembly (41) to FS
and splitter cam (28).
234.000 bellcrank assembly (40).
(7). Remove control rod (26) by sliding aft (3). Remove and discard cotter pin (2).
through tailboom opening. Remove nut (3), washers (4) and bolt
B. Force Limiting Control Rod Assembly (42) that attach bellcrank assembly (40)
Installation to FS 234.000 directional bracket
assembly (43).
(Ref. Figure 402)
Consumable Materials B. Directional Bellcrank Assembly

(Ref. CSPSPM) Installation
Item Nomenclature
(Ref. Figure 402)
C702 Lockwire
attaching FS 234.000 bellcrank
Make sure attached rod end assembly (40) to FS 234.000 directional
CAUTION does not twist. Damage to the bracket assembly (43).
rod end bearing can occur.
(1). Thread force limiting control rod (26) (3) attaching FS 231.500 control rod
onto rod end (60) attached to lateral assembly (25) and FS 234.000 direc
control rod (33) and splitter cam (28). tional control rod assembly (41) to
NOTE: If control rod (26) is a new assembly, re
move new rod end (60). Do not discard. (3). Torque nuts and install new cotter pins.
Page 420
(4). Secure baggage compartment soft 42. FS 234.000 Directional Control Rod
insulation roof panels (Ref. Section Assembly
25-50-00).
A. Directional Control Rod Assembly
41. FS 234.000 Directional Bracket Assembly Removal
A. Directional Bracket Assembly Removal (Ref. Figure 402)
(Ref. Figure 402) (1). Gain access to directional control rod
(1). Gain access to directional bracket
(Ref. Section 25-50-00). (2). Remove and discard cotter pins (2).
(2). Remove FS 234.000 bellcrank assembly Remove nuts (3), washers (4) and bolts
(40) (Ref. Section 67-20-00). (13) that attach both ends of FS
234.000 control rod assembly (41).
attach FS 234.000 directional bracket (3). Remove control rod assembly (41).
assembly (43) to airframe mounting
B. Directional Control Rod Assembly
surface.
Installation
B. Directional Bracket Assembly Installation
(Ref. Figure 402)
(Ref. Figure 402)
(1). Install bolts (44) and washers (4) (3) attaching both ends of FS 234.000
attaching FS 234.000 directional control rod assembly (41).
bracket assembly (43) to airframe
mounting surface. Torque bolts. (2). Verify directional control system rigging
(2). Install FS 234.000 bellcrank assembly
(40) (Ref. Section 67-20-00). (3). Torque nuts and install new cotter pins.
(3). Secure baggage compartment soft (4). Secure baggage compartment soft
insulation roof panels (Ref. Section insulation roof panels (Ref. Section
25-50-00). 25-50-00).
Page 421
43. FS 277.723 Directional Bellcrank 44. FS 277.723 Directional Bracket Assembly

Assembly
A. Directional Bracket Assembly Removal
A. Directional Bellcrank Assembly Removal
(Ref. Figure 402)
(Ref. Figure 402)
(1). Gain access to directional bracket
(1). Gain access to directional bellcrank assembly (49) through baggage
assembly (48) through baggage compartment soft insulation roof panels
compartment soft insulation roof panels (Ref. Section 25-50-00).
(2). Remove FS 277.723 directional bell
crank assembly (48) (Ref. Section
67-20-00).
(13) that attach FS 234.000 control rod (3). Remove bolts (19) and washers (4) that
assembly (41) to FS 277.723 directional attach FS 277.723 bracket assembly
bellcrank assembly (48). (49) to airframe mounting surface.
(3). Remove hardware that attaches Fwd B. Directional Bracket Assembly Installation
directional controls cable assembly (Ref.
Section 67-20-00) to bellcrank assem (Ref. Figure 402)
bly (48).
(4). Remove and discard cotter pin (2). attaching FS 277.723 bracket assembly
Remove nut (3), washers (4) and bolt (49) to airframe mounting surface.
(47) that attach directional bellcrank Torque bolts.
assembly (48) to FS 277.723 directional
bracket assembly (49). (2). Install FS 277.723 directional bellcrank
assembly (48) (Ref. Section 67-20-00).
(3). Secure baggage compartment soft
B. Directional Bellcrank Assembly insulation roof panels (Ref. Section
Installation 25-50-00).
(Ref. Figure 402) 45. Directional Fwd Cable Bracket
(1). Install bolt (47), washer (4) and nut (3) A. Directional Fwd Cable Bracket Removal
attaching FS 277.723 directional
(Ref. Figure 402)
bellcrank assembly (48) to FS 277.723
directional bracket assembly (49). (1). Gain access to Fwd cable bracket (50)
through baggage compartment soft
(2). Install hardware attaching Fwd insulation roof panels (Ref. Section
directional controls cable assembly (Ref. 25-50-00).
Section 67-20-00) to bellcrank assem
bly (48). (2). Remove hardware that attaches Fwd
directional controls cable assembly (Ref.
(3). Install bolt (13), washers (4) and nut (3) Section 67-20-00) to FS 277.723
attaching FS 234.000 control rod directional bellcrank assembly (48) and
assembly (41) to bellcrank assembly directional Fwd cable bracket (50).
(48).
(4). Torque nuts and install new cotter pins. (4 and 23) that attach Fwd cable
bracket (50) to airframe mounting
(5). Secure baggage compartment soft surface.
25-50-00). (4). Remove cable bracket (50).
Page 422
Original 67-20-00
B. Directional Fwd Cable Bracket B. Fan Control Outer Bellcrank Assembly

Installation Installation
(1). Install bolts (51 and 52) and washers (4 (1). Install bolt (58), washers (57) and nut
and 23) attaching Fwd cable bracket (56) attaching outer bellcrank assembly
(50) to airframe mounting surface. (39) to diverter assembly (Ref. Section
Torque bolts. 53-30-00).
(2). Install hardware attaching Fwd (2). Install bolt (59), washers (29) and nut
directional controls cable assembly (Ref. (3) attaching fan control lateral control
Section 67-20-00) to FS 277.723 rod assembly (46) to outer bellcrank
directional bellcrank assembly (48) and assembly (39).
directional Fwd cable bracket (50).
(3). Secure baggage compartment soft attaching force limiting control rod
insulation roof panels (Ref. Section assembly (26) to fan control outer
25-50-00). bellcrank assembly (39).
46. Fan Control Outer Bellcrank Assembly (4). Torque nuts and install new cotter pins.
A. Fan Control Outer Bellcrank Assembly 47. Fan Control Lateral Control Rod
Removal Assembly
(Ref. Figure 402) A. Fan Control Lateral Control Rod
Assembly Removal
(1). Gain access to diverter plate area (Ref.
Section 53-30-00). (Ref. Figure 402)
(2). Remove and discard cotter pin (2). (1). Gain access to diverter plate area (Ref.
Remove nut (3), washers (4) and bolt Section 53-30-00).
(38) that attach force limiting control
rod assembly (26) to fan control outer (2). Remove and discard cotter pins (2).
bellcrank assembly (39). Remove nuts (3), washers (29) and bolts
(59) that attach both ends of fan control
(3). Remove and discard cotter pin (2). lateral control rod assembly (46).
(59) that attach fan control lateral (3). Remove control rod assembly (46).
control rod assembly (46) to outer B. Fan Control Lateral Control Rod
bellcrank assembly (39). Assembly Installation
(4). Remove and discard cotter pin (55). (Ref. Figure 402)
(58) that attach bellcrank assembly (39) (1). Install bolts (59), washers (29) and nuts
to diverter plate assembly (Ref Section (3) attaching both ends of fan control
53-30-00). lateral control rod assembly (46).
(5). Remove outer bellcrank assembly (39). (2). Torque nuts and install new cotter pins.
Page 423
67-20-00 Original
48. Fan Control Inner Bellcrank Assembly 49. NOTAR Fan Control Shaft Assembly
A. Fan Control Inner Bellcrank Assembly A. Fan Control Shaft Assembly Removal
Removal
(Ref. Figure 402)
(Ref. Figure 402)
(1). Gain access to diverter plate area (Ref.
(1). Gain access to diverter plate area (Ref. Section 53-30-00).
Section 53-30-00).
Remove nut (3), washers (4) and bolt (13) that attach forward end of fan
(53) that attach fan control shaft control shaft assembly (54) to NOTAR
assembly (54) to fan control inner fan assembly (Ref. Section 53-30-00).
bellcrank assembly(45). (3). Remove and discard cotter pin (2).
Remove nut (56), washers (57) and bolt (53) that attach Aft end of fan control
(58) that attach bellcrank assembly (45) shaft assembly (54) to fan control inner
to diverter plate assembly (Ref Section bellcrank assembly (45).
53-30-00). (4). Remove shaft assembly (54).
(4). Remove inner bellcrank assembly (45). B. Fan Control Shaft Assembly Installation
B. Fan Control Inner Bellcrank Assembly (Ref. Figure 402)
Installation
(Ref. Figure 402) attaching Aft end of fan control shaft
assembly (54) to fan control inner
(1). Install bolt (58), washers (57) and nut
(56) attaching fan control inner bell
crank assembly (45) to diverter assem (2). Install bolt (13), washers (4) and nut (3)
bly (Ref. Section 53-30-00). attaching forward end of fan control
shaft assembly (54) to NOTAR fan
(2). Install bolt (53), washers (4) and nut (3) assembly (Ref. Section 53-30-00).
attaching fan control shaft assembly
(54) to fan control inner bellcrank (3). Verify directional control system rigging
assembly (45). (Ref. Section 67-20-00).
Page 424
Original 67-20-00
12 26
1
6
25
41
DIVERTER
PLATE ASSEMBLY
10 200 - 250 in-lb

21 22.59 - 28.24 Nm
18 10
REF. 12
19 15
16
20
17
4
REF. 1 19
2 22
4
23 10
3
7
2 9 2
4
8
4 10 2
3 4 4
3 REF. 6
4 5 11
3 3
24
2
5 4
REF. 6
REF. CLOSET REF. 6
CONTROL ROD
9G67 063
Figure 402. AntiTorque/Directional Control Upper Deck (Sheet 1 of 2)
Page 425
3 2
REF. 12 4 37
14
4
27
4 95 -110 in-lb
(4 PL) 36 10.73 - 12.43 Nm
4 33 61
13 60 62 REF. 26
34
13
4 4
4
35
3
4 REF. 63
3 2 35
64 (2 PL)
2 REF. 25 31 4
(2 PL) 28 32
32 (2 PL) 34
42
30 (2 PL) 3
19 2 3
4 2
REF. 30 (2 PL)
STRUCTURE 44 4
4
4
29 13
29 43
REF. 14
23
2 PLACES REF 41.

4
4 4
4
(2 PL) 13
50
23 40
47 (2 PL) 4 4
58 3
49 23 3
52
57 4 2
(2 PL)
38 51 2
59
26 39 13
4 4
4
4 29 4
2
3 4 3 58
48 3
2 29 2
19 57
3 59
55 56 57 2 53
46 29
29 4
REF. 41 2
45
2
3 4
4 3 57 3
13 54 55 56 2
9G67064
Figure 402. AntiTorque/Directional Control Upper Deck (Sheet 2 of 2)
Page 426

1. FS 155.500 FOD COVER 33. LATERAL CONTROL ROD ASSEMBLY
3. NUT 35. TRACK ROLLER
4. WASHER 36. BOLT
5. BOLT 37. BOLT
6. ACTUATOR INPUT CONTROL ROD ASSEMBLY 38. BOLT
7. DIRECTIONAL UPPER CLOSET BELLCRANK 39. OUTER BELLCRANK ASSEMBLY
ASSEMBLY 40. FS 234.000 DIRECTIONAL BELLCRANK ASSEMBLY
8. BOLT 41. FS 234.000 DIRECTIONAL CONTROL ROD ASSEMBLY
9. CONTROL DECK BRACKET ASSEMBLY 42. BOLT
10. WASHER 43. FS 234.000 DIRECTIONAL BRACKET ASSEMBLY
11. DIRECTIONAL ACTUATOR 44. BOLT
12. ACTUATOR OUTPUT CONTROL ROD ASSEMBLY 45. INNER BELLCRANK ASSEMBLY
13. BOLT
46. FAN CONTROL LATERAL CONTROL ROD ASSEMBLY
14. SPLITTER ASSEMBLY
47. BOLT
15. JAM NUT
48. FS 277.723 DIRECTIONAL BELLCRANK ASSEMBLY
16. LOCKWASHER
49. FS 277.723 DIRECTIONAL BRACKET ASSEMBLY
17. BOLT
50. DIRECTIONAL FWD CABLE BRACKET
18. ACTUATOR ATTACH BRACKET ASSEMBLY
51. BOLT
19. BOLT
20. ANTIROTATION ACTUATOR BRACKET 52. BOLT
21. BOLT 53. BOLT
22. BOLT 54. FAN CONTROL SHAFT ASSEMBLY
24. INTERIOR LIGHT SUPPORT CLIP ASSEMBLY 56. NUT
25. FS 231.500 DIRECTIONAL CONTROL ROD ASSEMBLY 57. WASHER
26. FORCE LIMITING CONTROL ROD ASSEMBLY 58. BOLT
27. BOLT 59. BOLT
28. SPLITTER CAM 60. ROD END
29. WASHER 61. JAM NUT
30. BOLT 62. LOCK WASHER
31. WASHER 63. SUPPORT ROD
Page 427
50. Rotating Cone Cover 51. Rotating Cone Assembly

(Ref. Figure 403)
(Ref. Figure 403)
C229 Sealant, Conductive Item Nomenclature
C235 Release Agent, Fluorocarbon C310 Primer
C702 Lockwire
A. Rotating Cone Cover Removal
(1). Remove screws (6) and washers (7). A. Rotating Cone Assembly Removal
(2). Carefully remove cover, do not damage

(1). Remove rotating cone cover.
preformed seal.
B. Rotating Cone Cover Installation (2). Remove and discard lockwire. Remove
bolts (8) and washers (9). Remove
NOTE: If seal is serviceable, proceed to step (6). rotating cone (1).
(1). Prepare mating surfaces for electrical
bond (Ref. CSP-SPM, Section (3). Slide rotating cone aft and remove.
20-50-00).
B. Rotating Cone Assembly Installation
(1). Install rotating cone on thruster.
Primer (C310)
(2). Apply fluorocarbon release agent
(C235) to rotating cone cover.
Sealant, Conductive (C229)
(2). Install bolts and washers wet with

primer (C310).
(3). Apply sealant (C229) to cone cover (3). Torque bolts and safety with lockwire
mating surface of rotating cone. (C702).
(4). Install cover on rotating cone and (4). Check that there is a gap between
maintain constant pressure of up to 50 contact (10) and cone surface.
psi (344.7 kPa). Remove excess sealant.
(5). Cure sealant for 7 days at room (5). Test contact for class L electrical bond
temperature or 4 hours at room (Ref. CSP-SPM, Section 20-50-00).
temperature followed by 2 hours at
190-210 5F (87.7-98.9 5C). (6). Install rotating cone cover.
(6). Torque cover attach screws.
(7). Make sure there is clearance of
(7). Test cover for class R electrical bond 0.12-0.25 in. (3.05-6.35 mm) between
(Ref. CSP-SPM, Section 20-50-00). rotating cone and fairings.
Page 428
52. Bearing Race, Rotating Cone Assembly Adhesive Promoter, Epoxy (C412)
(Ref. Figure 403)
(Ref. CSPSPM)
Item Nomenclature (5). Apply adhesive promoter (C412) to
bearing race.
C412 Adhesive Promoter, Epoxy
C402 Adhesive, Epoxy Adhesive, Epoxy (C402)
A. Bearing Race Removal

(1). Remove rotating cone assembly. (6). Apply epoxy adhesive (C402) 1.25 to
(2). Remove rivets (3 and 4) attaching 1.50 in. (3.175 to 3.81 cm) wide around
bearing race (2) in cone (1). inner mating surface of cone.
NOTE: Heating of race will weaken adhesive

and ease separating race from cone. CAUTION
Do not exceed 200F (93C). Maintain roundness of race ID during

CAUTION installation.
(3). Break bond between race (2) and cone Unconstrained roundness of assembly ID
(1). Remove race. shall not exceed 0.100 in (2.540 mm).
(4). Remove adhesive residue from inside Solvent Cleaner (C429)

surface of cone.
B. Bearing Race Installation
(1). Temporarily install bearing race in cone
without adhesive. (7). Install race in cone. Use solvent cleaner
(2). Measure dimension of cone between (C429) or equivalent to remove excess
inside mounting surface to forward face adhesive.
of race. Dimension should be 28.69 to
(8). Cure for 16 to 24 hours at ambient
28.71 in. (72.87 to 72.92 cm).
temperature or heat to 170 to 190F
(3). Remove race and trim cone if dimension (76.7 to 87.7C) for 1 hour.
is not met.
(9). Install rivets.
(a). HS5422 rivet height shall extend on
inside of race 0.035 to 0.050 in.
(0.889 to 1.27 mm). If dimension is
not met, sand down rivet or install
(4). Clean mating surfaces of cone and race shorter grip length.
with solvent cleaner (C429) or equiva
lent and air dry for fifteen minutes (10). Install rotating cone assembly.
Page 429
1 7
2
5
9 (3 PL)
VIEW ROTATED 8 (3 PL)
NOTE 3
10

3(3PL)
(NOTE 2)
NOTE 4 VIEW ROTATED
4 (NOTE 1) NOTES:
1. RIVET IS ALIGNED WITH CENTER OF OPENING.
2. RIVETS EQUALLY SPACED.
3. ANY MEASURABLE GAP.
4. LIQUID SHIM. 9G67-047B
1. ROTATING CONE ASSEMBLY 6. SCREW

2. BEARING RACE 7. WASHER
3. NAS1919 RIVET 8. BOLT
4. HS5422 RIVET 9. WASHER
5. ROTATING CONE COVER 10. LIGHTNING STRIKE CONTACT
Figure 403. Rotating Cone Assembly

53. Sector Support Bracket (4). Remove screws (33) and washers (16).
Remove support bracket (30).
(Ref. Figure 404)
B. Sector Support Bracket Installation
Special Tools
(Ref. CSPSPM) (1). Install sector support bracket, screws,
Item Nomenclature and washers. Torque screws.
T2015 Tensiometer
(2). Install nut and washer. Torque nut and
A. Sector Support Bracket Removal
(3). Adjust tension of rotating cone control
(1). Remove rotating cone. cable to 36-44 lbs. (16.33-19.96 kg),
use tensiometer (T2015). Install
(2). Remove locking clips from one rotating
turnbuckle locking clips.
cone control cable turnbuckle (5) and
remove tension from forward rotating
cone control cables (6). (4). Install rotating cone.
(3). Remove and discard cotter pin (25). (5). Do the Anti-Torque/Directional
Remove nut (24) and washer (16). Controls Travel/Rigging Verification.
Page 430
54. Sector Guard Clip (3). Install sector support bracket.

(Ref. Figure 404) 55. Sector
(Ref. Figure 404)
(Ref. CSPSPM)
Item Nomenclature Consumable Materials
C310 Primer (Ref. CSPSPM)
Item Nomenclature
C502 Glass Fiber, Sheet, Laminate
C702 Lockwire
A. Sector Guard Clip Removal Special Tools

(1). Remove sector support bracket. (Ref. CSPSPM)
Item Nomenclature
(2). Remove rivets (32). T2015 Tensiometer
(3). Break fiberglass bond and remove and
sector guard clip (31). A. Sector Removal
B. Sector Guard Clip Installation (1). Remove sector support bracket.
Glass Fiber, Sheet, Laminate (C502) (2). Remove remaining locking clips from
rotating cone control cables turnbuckle
(5) and disconnect forward (6) and aft
cables (7).
(1). Cut glass fiber laminate (C502) to (3). Remove and discard lockwire. Remove
dimension necessary to give dissimilar bolt (4) and washer (3).
material protection between sector
(4). Disconnect rotating cone control rod (2)
guard clip and sector support bracket.
(5). Remove bushing (40) and sector (36).
Primer (C310)
B. Sector Installation
(1). Install sector and bushing.
(2). Connect rotating cone control rod and
(2). Put sector guard clip and glass fiber install bolt and washer. Torque bolt and
laminate (C502) in their installed safety with lockwire (C702).
position. Install rivets wet with primer
(C310). (3). Install sector support bracket.
Page 431
56. Sector Rigging Plate B. Sector Support Shaft Installation
(Ref. CSPSPM)
Item Nomenclature (1). Apply sealing compound (C205) to
C205 Sealing Compound mating surfaces of sector rigging plate,
sector support shaft, and sector brack
et.
A. Sector Rigging Plate Removal
(2). Install sector support shaft, sector
(1). Remove sector. rigging plate, bolts, and washers.
Torque bolts.
(2). Remove bolts (38), washers (16), and (3). Install washers.
sector rigging plate (39).
(4). Install sector.
B. Sector Rigging Plate Installation
58. Sector Support Shaft Bracket
(Ref. Figure 404)
(Ref. CSPSPM)
Item Nomenclature
mating surfaces of sector rigging plate
and sector support shaft. C310 Primer
(2). Install sector rigging plate, bolts, and A. Sector Support Shaft Bracket Removal
washers. Torque bolts.
(1). Remove sector support shaft.
(3). Install sector.
(2). Remove rivets (44) and sector support
57. Sector Support Shaft bracket (42).
B. Sector Support Shaft Bracket Installation
(Ref. Figure 404)
(Ref. CSPSPM)
Item Nomenclature
C205 Sealing Compound (1). Apply sealing compound (C205) to
mating surfaces of sector support shaft
bracket and thruster.
A. Sector Support Shaft Removal
Primer (C310)
(1). Remove sector.
(2). Remove washers (22 and 37).
(3). Remove sector rigging plate. (2). Install sector support shaft and rivets.
Install rivets wet with primer (C310).
sector support shaft (41),. (3). Install sector support shaft.
Page 432
59. Rotating Cone Forward Control Cable (2). Connect forward and aft control cables
to turnbuckles.
(Ref. Figure 404) (3). Adjust tension of rotating cone control
cable to 36-44 lbs. (16.33-19.96 kg),
use tensiometer (T2015). Install
turnbuckle locking clips.
(Ref. CSPSPM) (4). Install rotating cone
Item Nomenclature (5). Do the Anti-Torque/Directional
C702 Lockwire Controls Travel/Rigging Verification.
60. Rotating Cone Aft Control Cable
Special Tools (Ref. Figure 404)
(Ref. CSPSPM)
Item Nomenclature Consumable Materials
(Ref. CSPSPM)
T2015 Tensiometer
Item Nomenclature
A. Rotating Cone Forward Control Cable Special Tools

Removal (Ref. CSPSPM)
Item Nomenclature
NOTE: This task is typical for left or right ro T2015 Tensiometer
tating cone forward control cable.
A. Rotating Cone Aft Control Cable Removal
(1). Remove rotating cone. NOTE: This task is typical for left or right ro
tating cone aft control cable.
(2). Remove locking clips from control cable (1). Remove lightening strike shield.
turnbuckle (5). (2). Remove locking clips from control cable
turnbuckle (5).
(3). Disconnect rotating cone forward (3). Disconnect rotating cone aft control
control cable (6) from turnbuckle (5). cable (7) from turnbuckle (5).
(4). Remove cable retaining pins (49).
(4). Remove and discard lockwire. Remove (5). Remove screw (26).
screw (35) and washer (16). Disconnect (6). Remove aft control cable.
forward control cable (6).
B. Rotating Cone Aft Control Cable
Installation
(5). Remove forward control cable. NOTE: This task is typical for left or right ro
tating cone aft control cable.
B. Rotating Cone Forward Control Cable (1). Put aft control cable on control cable
Installation. drum.
NOTE: This task is typical for left or right ro
tating cone forward control cable.
(1). Connect forward control cable to sector (2). Install screw, install wet with sealing
and install screw and washer. Torque and locking compound (C225). Torque
screw and safety with lockwire (C702). screw.
Page 433
(3). Install forward and aft control cable Primer (C310)

turnbuckle.
(4). Install cable retaining pins.
(5). Adjust tension of rotating cone control (1). Install pulley bracket, laminated
cable to 36-44 lbs. (16.33-19.96 kg), washers, bolts, and washers. Install
use tensiometer (T2015). Install bolts wet with primer (C310). Torque
turnbuckle locking clips. bolts.
(2). Install rotating cone aft control cables.

(6). Install lightening strike shield.
C. Control Cable Pulley Removal
(7). Do the Anti-Torque/Directional
Controls Travel/Rigging Verification. NOTE:
This task is typical for left or right control
cable pulley.
61. Control Cable Pulley and Bracket
It is not necessary to remove cable from
control cable drum.
(Ref. Figure 404)
(1). Remove rotating cone aft control cable.
Consumable Materials (2). Remove and discard cotter pins (50).
(Ref. CSPSPM) Remove nut (51), washers (52), and bolt
Item Nomenclature (54). Remove pulley (45).
C310 Primer
D. Control Cable Pulley Installation
NOTE: This task is typical for left or right con

A. Pulley Bracket Removal trol cable pulley.
NOTE: It is not necessary to remove cable from (1). Install cable pulley, bolt, washers, and
control cable drum. nut. Torque nut and install new cotter
pin.
(1). Remove rotating cone aft control cables. (2). Install rotating cone aft control cable.
(2). Remove bolts (47), washers (16), and 62. Control Cable Drum
laminated washers (48). Remove pulley
bracket (46). (Ref. Figure 404)
A. Control Cable Drum Removal

B. Pulley Bracket Installation
(1). Remove rotating cone aft control cables.
NOTE:
Adjust thickness of laminated washers to Remove nut (24), washers (23, 12, and
fill clearance between thruster flange and 22), and control cable drum (21).
pulley bracket.
B. Control Cable Drum Installation
It is possible that adjustment of lami
nated washers is not be necessary if NOTE: Add washers (23) under nut as neces
pulley bracket or thruster is not a replace sary for nut alignment with cotter pin hole.
ment. Minimum one washer.
Page 434
(1). Install control cable drum, washers, collar, use sealing compound (C205)
and nut. Torque nut and install new (Ref. CSP-SPM).
cotter pin.
(5). Install washers on drum bracket shaft.
(2). Install rotating cone aft control cables.
(6). Install drum.
63. Drum Bracket (7). Do the Anti-Torque/Directional
Controls Travel/Rigging Verification.
(Ref. Figure 404)
64. Wire Braid Ground Jumper
(Ref. Figure 404)
(Ref. CSPSPM)
Item Nomenclature
C205 Sealing Compound Consumable Materials
(Ref. CSPSPM)
C310 Primer Item Nomenclature
A. Drum Bracket Removal. C310 Primer
(1). Remove drum.
A. Wire Braid Ground Jumper Removal
(2). Remove washers (19 and 20).
(1). Remove rotating cone.
(3). Remove collars (27), washer (16),
ground jumper (14), wire braid ground (2). Remove collar (27), washer (16), ground
jumper (55), and pin rivets (28 and 29). jumper (14), and wire braid jumper
Remove drum bracket (8). assembly (55).
B. Drum Bracket Installation (3). Remove pin rivet (34).

(4). Remove rivets (53) and washers (16).
(1). Prepare mating surfaces of drum
bracket and ground jumpers for NOTE: Remove sealing compound as necessary
electrical bond (Ref. CSP-SPM). to remove wire braid ground jumper.
Primer (C310) (5). Remove one terminal from end of wire
braid ground jumper and remove wire
braid ground jumper.
thruster.
(2). Install pin rivets, wire braid ground
jumper, ground jumper, washer, and B. Wire Braid Ground Jumper Installation
collars. Install pin rivets wet with
primer (C310). NOTE:
Apply sealing compound (C205) between
(3). Test between thruster attach frame and wire braid and truster.
drum bracket for class L electrical
Apply a minimum of 0.75 in. (19 mm) cir
cular area at attach rivets.
Sealing Compound (C205) Apply a minimum of 0.75 in. (19 mm)
width where wire braid goes through
thruster.
(1). Put wire braid ground jumper through
stationary thruster.
(4). Environmentally seal pin rivet, braid
ground jumper terminal lug, ground (2). Install terminal(s) on wire braid ground
jumper terminal lug, washer, and jumper (Ref. CSP-SPM).
Page 435
(3). Prepare mating surfaces of the two B. Rotating Cone Support Bearing
ground jumper terminal lugs and Installation
control cable drum bracket for electrical
bond (Ref. CSP-SPM). (1). Install support bearing, washers, and
bolt. Torque bolt.
Before you install rotating cone,
CAUTION make sure all support bearings
turn freely.
(2). Install rotating cone.
(4). Apply sealing compound (C205) at
necessary locations. 66. Lightning Strike Shield
(Ref. CSPSPM)
Item Nomenclature
(5). Install pin rivet in thruster and control C205 Sealing Compound
cable drum bracket. Install wet with C502 Glass Fiber, Sheet, Laminate
primer (C310).
C717 Tape, Polyethylene
(6). Install wire braid jumper, ground
jumper, washer, and collar.
A. Lightning Strike Shield Removal
(1). Remove rotating cone.
NOTE: Ground jumper removal is not neces
sary if lightening strike shield is not re
placed.
(7). Install rivet, washer, and wire braid
(2). Remove rivet (18) and washer (16).
jumper terminal lug. Install wet with
sealing compound (C205). (3). Disconnect ground jumper (14).
(8). Install rivets and washers that attach (4). Remove bolts (17), washers (16), and
wire braid to thruster. Install wet with lightning shield (15).
B. Lightning Strike Shield Installation
(9). Test between thruster attach frame and
drum bracket for Class L electrical Glass Fiber, Sheet, Laminate (C502)
(10). Environmentally seal rivet and collar
with sealing compound (C205) (Ref.
CSP-SPM). (1). Cut glass fiber laminate (C502) or
(11). Install rotating cone polyethylene tape (C717) to 1.0 X 1.0 in
(25.4 X 25.4 mm), and cut 0.191 in
65. Rotating Cone Support Bearing (4.85 mm) hole in center.
(Ref. Figure 404) (2). Put lightening strike shield in its

installed position.
A. Rotating Cone Support Bearing Removal
(3). Install fiberglass or tape between
(1). Remove rotating cone. lightning strike shield and thruster
vertical stiffeners (four places).
(2). Remove bolt (9), washers (10 and 13),
and support bearing (11). (4). Install bolts and washers. Torque bolts
Page 436
(5). If ground jumper was removed, prepare (3). Remove collar (27), washer (16), and
mating surfaces of lightening strike jumper assembly (14).
shield and ground jumper for electrical
bond (Ref. CSP-SPM). B. Ground Jumper Installation
Make sure there is no interfer (1). Prepare mating surfaces of ground

CAUTION ence between ground jumper jumper, lightening strike shield, wire
and rotating cone. braid ground jumper, washer, and drum
bracket for electrical bond (Ref. CSP-
(6). If ground jumper was removed, install SPM).
rivet and washer.
Make sure there is no interfer
(7). Test between lightening strike shield CAUTION ence between ground jumper
and drum bracket for Class L electri and rotating cone.
Primer (C308)
(2). Connect ground jumper to lightening

(8). If ground jumper was removed, envi
strike shield and install rivet and
ronmentally seal ground jumper, use
sealing compound (C205) (Ref. CSP- washer. Install rivet wet with primer
(C308).
SPM).
(9). Install rotating cone. (3). Connect ground jumper to drum
bracket and install washer and collar.
67. Ground Jumper, Lightning Strike Apply primer (C308) to end of pin rivet.
(Ref. Figure 404) (4). Test between lightening strike shield

and drum bracket for Class L electri
(Ref. CSPSPM) Sealing Compound (C205)
Item Nomenclature
C308 Primer
A. Ground Jumper Removal (5). Environmentally seal ground jumper,

use sealing compound (C205) (Ref.
(1). Remove rotating cone. CSP-SPM).
(2). Remove rivet (18) and washer (16). (6). Install rotating cone.
Page 437
2 4 15
3 NOTE
16 (6 PL)
6
17 (6 PL)
7
18
13 10 11 10 9
VIEW ROTATED 8 14
16 PL 5
16
3 PLACES 27
20
21
22
28
53 25
16 19
53 (5 PL) 24
12 23
54 16 (5 PL)
26 26
16 55
REF 8
LOOKING INBOARD
LOWER LEFT SIDE 29
REF 14
16
27
25 24 32 (2 PL) 51 (2 PL)

CSP 900rmm 2 - I1r34p

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Manual: CSP-900RMM-2, Rotorcraft Maintenance Manual

Models: MD900 Helicopters

Remove Pages Insert Pages Chapter 12

Rotorcraft Maintenance Manual

SERVICING AND MAINTENANCE

Copyright E 1999-2010 by MD Helicopters, Inc. Reissue No. 1: 24 December 1997

PROPRIETARY RIGHTS NOTICE

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ROTORCRAFT MAINTENANCE MANUAL (CSP900RMM2)

RECORD OF TEMPORARY REVISIONS

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RECORD OF TEMPORARY REVISIONS (CONT.)

Rev. Date Date Rev. Date Date

ROTORCRAFT MAINTENANCE MANUAL (CSP900RMM2)

INSERT LATEST CHANGE PAGES, DESTROY SUPERSEDED PAGES

Cover/Title 201 and 202 . . . . . . . . . . . . . . . . . . . . Revision 29

052010 205 and 206 . . . . . . . . . . . . . . . . . . . . Revision 7

201 thru 208 . . . . . . . . . . . . . . . . . . . . Original 601 thru 606 . . . . . . . . . . . . . . . . . . . . Revision 34

280000 801 thru 804 . . . . . . . . . . . . . . . . . . . . Revision 1

2 thru 5/(6 blank) . . . . . . . . . . . . . . . . Original 401 thru 404 .................... Revision 33

601 thru 603 . . . . . . . . . . . . . . . . . . . . Revision 25 403 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Original

609 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revision 31 111 and 112 . . . . . . . . . . . . . . . . . . . . Revision 11

2 thru 4 . . . . . . . . . . . . . . . . . . . . . . . . Original Chapter 78

050000 Continued Airworthiness 256000 Emergency First Aid Kit

09 Towing 32 Landing Gear

63 Transmission and Drive System 71 Powerplant

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TABLE OF CONTENTS (Cont.)

C. Engine Conversion Modification from 900 CONFIG - PW207E Engine conversion

3. Helicopter Description The landing gear is a horizontal skid-type

A. Rotorcraft Maintenance Manual information possibly beneficial to the owner/

ROTOR SYSTEM EMPENNAGE

Figure 1. Helicopter Major Components

Figure 2. ATA Numbering System

10. References 12. Service Bulletins and Letters

Before you start a task, read the Warnings and

7. Warning and Caution Statements 8. Directives and Related Manufacturers

Table 201. Directives and Related Manufacturers Publications (1)

MDHI Rotorcraft Maintenance Manual CSP900RMM2

MDHI Rotorcraft Maintenance Manual CSP900RMM3

MDHI Illustrated Parts List (IPL) CSP900IPL4

MDHI Standard Practices Manual CSPSPM

Pratt & Whitney Canada Illustrated Parts Catalog 3038326

Pratt & Whitney Canada Illustrated Parts Catalog (PW207E) 3049725

Goodrich Corp. (Formerly TRW, Lucas Maintenance Manual 23700

Table 201. Directives and Related Manufacturers Publications (Cont.)(1)

Wire Strike Protection System