2294

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ATP Grid Index to Manufacturers Publications:
MD Helicopters Inc.
500 Series (369) Helicopters
600N
Optional Equipment Supplements
Section Topic
General Information
CSP-003 Engine Auto Reignition (P/N 369H90118-513,-515)

Table of Contents
Manufacturers Introduction
Record of Revisions
Record of Temporary Revisions
List of Effective Pages
Reference Sheets
Foreword
Illustrated Parts List

Engine Automatic Reignition Equip (Commercial Config)
Engine Automatic Reignition Equip (Military Config)
Maintenance Instructions
Initial Modification (Installation) Instructions
CSP-008 Attitude Gyro Indicator (P/N 369H90038-501)

Manufacturers Indroduction
Record of Revisions
Table of Contents
Foreword

Attitude Gyro Indicator Installation
Installation Instructions
04/19/2002 Copyright Aircraft Technical Publishers Page 1 of 9
HU 0201 OX)
Section Topic
CSP-009 Direction Gyro Indicator (P/N 369H90039-501,-503)

Record of Revisions
Table of Contents
Foreword

Directional Gyro Indicator Installation
CSP-010 IVSI (Instant Vert Speed Ind) (P/N 369H90044,-503)

Record of Revisions
Table of Contents
Foreword

Vert Speed Indicator Instl Bolt Light 369E/F Hlcptr
Vert Speed Indicator Instl 369HS 3699 Helicopter
CSP-012 Transpondr Instl (KT-76)(369H90073,-501,-503,-501)

Record of Revisions
Table of Contents
Foreword

KT-76 Transponder Equipment
CSP-015 ADF (KR85) (369H90067,-501,-51,-61)

Record of Revisions
HU 0201 OX
Section Topic

Table of Contnents
Foreword

Automatic Direction Finder Installations
Automatic Direction Finder Antenna Filter Instls
ADF Alternate Indicator Receiver Instl Provisions
CSP-016 Nav/Comm Transcvr Instl (369H90071,-503,-507,-509)

Record of Revisions
Table of Contents
Foreword

KX170A/B, 1753 KY195B King Transceiver Coupler Instl
KX170A/B, 175B KY195B King Transceiver System
ADF/VHF-Nav Antenna
ADF/VHF-Nav Antenna Installation Extended Landing Gear
CSP-017 Integratd Intrphone (ICS) Instl (P/N 369H90068-11)

Record of Revisions
Table of Contents
Foreword

Integrated Interphone (ICS) System Installation
CSP-019 Auto Direction Finder (KR 86) (P/N 369H90056.-501)

Record of Revisions
Table of Contents
Foreword
HU 0201 OX
Section Topic

KR 86 Automatic Direction Finder
CSP-020 Radio Instl (ASB-125/60) (369H90144-501,-503,-505)

Record of Revisions
Table of Contents
Foreword

ASB-125/60 Radio Installation
Power Amplifier/Power Supply Installation
SWR Sensor Antenna Installations
CSP-023 Cyclic Stik Grip Kit Instl (P/N 369H90129-31.-505)

Record of Revisions
Table of Contents
Foreword

Cyclic Stik Grip Kit Assembly
Maintenance Intructions
CSP-026 Litter Instl (P/N 369H9011-511,-517,-519,-521)

Record of Revisions
Table of Contents
Foreword

Litter Kit Installation
High Head Room Door Kit
HU 0201 OX
Section Topic
AFT Stanchion Assembly

Passenger Litter Door Retainer Installation
Litter Kit Provisions
CSP-029 Passenger/Cargo Hoist Sys (P/N 369H90070-521,-522)

Record of Revisions
Table of Contents
Foreword

Hoist Kit Components
Passenger/Cargo Door Retainer Installation
Hoist Assembly
CSP-032 Searchlight Installation (P/N 369H90142)

Record of Revisions
Table of Contents
Foreword

Manually Operated Searchlight Installation
CSP-033 Public Address Siren Sys Instl (P/N 369H90143)

Record of Revisions
Table of Contents
Foreword
HU 0201 OX)
Section Topic

Public Address Siren System Installation Kit
CSP-036 Seating Belts for Four (P/N 369H90035-501,-503)

Record of Revisions
Record of Tenporary Revisions
Table of Contents
Foreword

Seating Belts for Four Assy 369E/F Helicopters
Seating Belts for Four Assy 3690 Helicopters
CSP-071 Litter Installation (P/N 3690290170)

Record of Revisions
Table of Contents
Foreword

Litter Kit Installation
Litter High Door Installation
Bubble Door Litter Kit Adapter Assembly
Bubble Door Adapter Assembly
Prop Installation
Attendant Seat Installtion
Litter Kit Assembly
Litter Door Structural Installation
Litter Kit Support Arm Assembly
Vertical Canted Station 78.50 Litter Kit Support Instl
HU 0201 OX
Section Topic
CSP-084 TDR-950 Transponder System

Record of Revisions
Table of Contents
Foreword

TDR-950 Transponder System, Early Configuration
TDR-950 Transponder System, Current Configuration
CSP-087 Float Lamp Assembly (P/N 3690292032)

Record of Revisions
Table of Contents
Foreword

Float Lamp Assembly
CSP-089 Dual Starting Kit (P/N M30306)

Record of Revisions
Table of Contents
Foreword

Dual Starting Kit
CSP-094 Engine Air Inlet Diverter Kit (P/N See TP)
HU 0201 OX
Section Topic
Record of Revisions
Table of Contents
Foreword

Engine Air Inlet Diverter 5000
Engine Air Inlet Diverter 500E
Engine Air Inlet Diverter 500D/E (369092045)
CSP-100 250-C20R/2 Eng Conversion Instl Kit (P/N See TP)

Record of Revisions
Table of Contents
Foreword

250-C20R/2 Engine Installation Kit (Fig 1-1)
CSP-102 Upgraded Trans Conversion Model 3690,E,FF,500N HEL

Letter of Transmittal (Highlights of Changes)
Record of Revisions
Table of Contents
Foreword

Mod Kit Instl Airframe Structure Upgrade Transmission
Upgraded Main Rotor Driveline Modification Kit
Aircraft Technical Publishers Page 8 of 9

04/19/2002 Copyright
HU 0201 OX
Section Topic
CSP-103 Litter Kit Installation (P/N 600N90710)

Record of Revisions
Table of Contents
Maintenance Practices
Initial Installation
End of Index
HU 0201 OX)
CSP
003
Publication No. CSP-003
illustrated Parts List

and
NIaintenance Instructions
with initial
FOR
ENGINE AUTOMATIC REIGNITION
Part No. 369B90118-513 and 369B90118-515
USED ON HUGHES 500D AND
500MD (MODEL 369D) HELICOPTERS
THIS REISSUE SUPERSEDES ALL

PREVIOUS ISSUES OF THIS PUBLICATION
Hughes Helicopters n,..l.,~ /..II.~,.. r...a
COD775211
Issued 1 February 1978

NI FG.
INTRO
Opt Eqpt ,vlanual CSP-003
INILlr i*rIll CB*NGID )~GII. 0r~llOl IYPrl~lOtO ~*tll.

LIST OF EFFECIIYE PAGES THE P~STERISK (NOICPITES PACES CHANCEO. *DDED. OR DELETED BY THE CURRENT CHANCE.
Pale Date
Title Original
hthru B. Original
C13lank Original
1 Original
ii E3iank Original
F-l Original
F-2 Dlank Original
1-1 thru 1-5..............., Original
1-6 Dlank Original
2-1 thru 2-7 Original
2-8 Blank Original
3-6 Dlank Original
Opt Eqpt Manual
CSP-003
HUGHES TECI-INICAL MANUAL RECOMMENDED CHANGE REPORT
This manual has been prepared and distributed by the Commercial Service Puhlications Department
and is intended for by personnel responsible for the maintenance of Hughes Helicopters. Periodic
use
revision of this manual will be made to incorporate the latest information. I, 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.
Hughes Helicopters
Centinela and Teale Streets
Culver City, California 90230
Attention: J. J. Dillon, Commercial Service Publications

2T17B
Originator
Address
Hook Identification: Date:
Helicopter Model Volume Title
Issue Date _
Revision No.
Discrepant Area las applicable): Revision Date
Page Number(s) Paragraph Number(s)
Step(s) Table Number(s)
Figure Number(s)
nemarks/necomm endations
BiC
BEC~RB 8F REVISION%
CSP-003
MFG REV
NO DESCRIPTION ISSUEDATE ATPREVDATE INSERTEDBY
RECORD OF TEMPORARY REVISIONS
ATP REV INSERT DATE REV REMOVE

REV NO DESCRIPTION ISSUE DATE DATE BY REMOVED INCOR BY
CSPIOO~ Opt Eqpt Manual Table ol Contents
ENGINE AUTOMATIC REIGNITION
TABLE OF CONTENTS
Section Page
FOREWORD F-l
F-l. Purpose and Content o~

This Manual F-l
F-3. Applicability F-l
F-5. Compatibility of Combined
Optional Equipment..... F-1
Organization ol Contents F-l
F-9, Use of This Manual F-l
F-ll. Related Publications F-l
F-13. Literature Changes uid
Revisions F-l
1 ILLLSTRATED PARTS LIST
1-1. Scol~andContents 1-1

1-3. Group Asseinbly
Parts List 1-I
1-5. Illustrvlions r-1
1-I. Usal,leon Code
Section Page
2 MAINTENANCE INSTRUCTIONS.. 2-1
21. Generaltnlormation 2-1

a-5. Operational Check. 2-1
2~1. Troubleshootln6! 2-1
2-9. Removal and
installation 2-1
2-11. Inspection 2-1
2-13. WlringDLapram~ 2~4
3 1MTIAt MOD(FICAT1ON
(CJSTA L~AT1ON)
INSTRUCTIONS 3~1
GenenlInlormltlon 3-1
Preparation lor
Installation SII
3-6. Installation of En~Lne
Automatic Reignition
System
3-10. Weipht and Dalnnce..... 3~1
;1;1
E) Huehl Hlicopfers
REFERENCE SHEET
SERVICE IT~FORMATION NOTICES AND LETTERS
Action Reference: When performing maintenance of engine automatic

reignition kit installation, refer to Service Information
Letter No. DL-18.
HMI Reference: Insert this sheet in IPL and Maintenance Instructions

for Engine AutomaticReignition Kit Installation,
Publication No. CSP-003, page 1-3.
This reference sheet shall be kept as a part of the
manual until the data is incorporated at the next
revision of Publication No. CSP-003.

Hughe. Helicopters
REFERENCE SHEET
SERVICE INFORMATION NOTICES AND LETTERS
Action Reference: When performing maintenance or inspection of the

automatic reignition installation, refer to Service
Information Notice No. DN-69 for a polarity check of
the diode assemblies.
HMI Reference: Insert this sheet in CSP-003 IPL and Maintenance Manual
for the automatic reignition installation, Section 3,
page 3-1, figure 3-7.
This reference sheet shall be kept as a part of
the manual until the data is incorporated at the
next revision of CSP-003.

CSP-OOJ Opt Eqpt Manual Forewo rd
FO R EWO R D
F-l, PURPOSE AND CONTENT OF THIS Each section is organized to provide comprehen-
MANUAL. sive coverage of entire systems, major equipment
groupings, and major components that are similar
F-2. This manual supplements information con- or associated. Procedures for each of these are
tained in HMI- Vol 1 and 369D- IPC. and contains presented in sequenceas defined in section I.
instructions for initial installation and continuing HMI Vol 1.
maintenance for 3691190118-513 (commercial) and
3691190118-515 (military) engine automatic reigni-
F-9, USE OF THIS MANUAL.
tion equipment. Weight and balance data is in-
cluded. This manual also contains parts lists for
procuring replacement parts for the engine auto- F-10, This manual is for use by operators of
matic reignition equipment, the Model 369D helicopter equipped with engine
automatic reignition equipment. Althoughthis
F-3. APPLICABILITY. manual is a separate publication, it should be
kept with HMI Vol 1, HMI Vol 2, 369D IPC
F-4. Engine automatic reignition equipment is and other handbooks listed in section i. HMI
applicable for use on any Hughes 500D or 500MD Vol 1 that form the primary information file for
(Model 369D) helicopter, the helicopter.
F-5. COMPATIBILITY OF COMBINED

F-ll. RELATED PUBLICATIONS.
OPTIONAL EQUIPMENT.
F-12. Reference is made to applicable portions

F-6. Forcompatibility information on which of HMI Vol 1 and 369D ZPC as required to
optional equipment may or may not be used in accomplish instructions contained herein.
combination at the same time, refer to section
21, HMI- Vol 1.
F-13. LITERATURE CHANGES AND REVISIONS.
F-7. ORGANIZATION OF CONTENTS.
F-14. Changes and revisions to contents of this
F-8, The contents of this manual are grouped manual are made as defined in section 1.
into sections as outlined in the Table of Contents. HMI Vol 1.
F-1F-2
CSP-005 Opt Eqpt Manual Section 1
SECTION 1
ILLUSTRATED PARTS LIST
1-1. SCOPE AND CONTENTS. 1-5. ILLUSTRATIONS.
1-2. This illustrated parts list provides, by 1-6. Illustrations are provided for each group
means of text (parts lists) and companion illus- assembly parts list. Each illustration is exploded
trations, a complete parts definition of 36911 to the extent necessary to show parts relationship
90118-513 and 3691190118-515 Engine Automatic for the complete engine automatic reignition
Reignition Equipment; manufactured by Hughes equipment.
Helicopters, Culver City, California.
1-7. USABLE ON CODE.
NOTE: The illustrated parts list is organized
and presented in the same manner as the 1-8. The USABLEON CODE column located at
369D Series Illustrated Parts List (369D the right-hand side of the Group Assembly Parts
IPC). (For information on use, refer to the List pages indicates the effectivity of parts by
369D IPC. aircraft serialnumber. In many cases two dif-
ferent parts are listed, one representing the
1-3. GROUP ASSEMBLY PARTS LIST. original installation and another representing an
improved replacement item. Alphabetic codes
1-4. The parts lists furnish information for pro- are used to indicate the aircraft serial number
curing replacement parts for the engine automatic applications of a given part. When no USABLE
reignition equipment, and shall not be used for ON CODE is listed items are understood to have
any other purpose. full effectivity.
1-1
Section 1 Opt Eqpt Manual CSP-OOJ
11
I~
.li
I-
r (.il
,IIs 17
Q
RELAY
INSTALLATION
OLEO
25 SUPPORT
21 20 E
29
3
c-
29
28 8
O
22C
2s to
s DIODE ISOLATOR
P j ASSEMBLY
I, P"P
19 23
30
O 27 4
SWITCH INSTALLATION
QC\
I
ENG INE COMPARTMENT
CI
i
x
5.
I: 47-011A
Figure 1-1. Engine automatic reignition equipment (commercial configuration)
1-a
FIG. UNITS USABLE

INDEX PART DESCRIPTION PER ON
NO. NO. ASSY CODE
1-1- 369H90118-513 AUTOMATIC ENGINE REIGNITION KIT I 1

-1 6870885 1 IGNITION EXCITER. 1
43754 1 IGNITION EXCITER(Interchangeable with.... 1
6870885)
6870891 1 IGNITION EXCITER (Interchangeable with. 1
6870885)
10-387150-1 I IGMTION EXCITER (Interchangeable with. 1
6870885)
-2* FHE1GI-SA IGNITER 1
6843984 IGNITER (Interchangeable with FHE161-9A)... 1
(YB63- 1)
3691190118-51 1 DIODE ISOLATORASSEMBLY I 1
-3 MS20341-6C NUT. a
-4 MS35338-136 1.. WASHER 1 2
-5 NAS6a0C6L I.. WASHER 1 4
-6 MS35a75-229 1.. SCREW 2
-7 AN316-4 I.. NUT 1 2
-8 IN3210 I.. DIODE (CR1, CR2) 2
-9 369H90118-5 BUS 1
-10 36 911901 18- 3 1 BRACKET I 1
-11 MS21042L02 I NUT 1 4
-12 NAS620Ca 1 WASHER 8
-13 MS35a06-203 1 SCREW 4
3691190118-71 RELAY ASSEMBLY (K104) 1
-14 369B4243 1.. RELAY I 1
369A4557 1 RELAY (Interchangeable with 369114243). 1
3691190118-91 1 RELAY ASSEMBLY (K304) 1
-15 369B4243 1.. RELAY I 1
36 91145 57 1 RELAY (Interchangeable with 369114243). 1
-16 NAS600-4 SCREW 4
-17 AN960PD4L I WASHER 1 4
-18 369112505-169 1 BRACKETASSEMBLY I 1
-19 MS35059-22 1 SWITCH(S11) I 1
-20 MSa 1042L08 1 NUT 1
-21 NAS620C8L WASHER 1 2
-23 369B90~18- 17 1 SUPPORT 1
3691190118-101 1 SWITCH ASSEMBLY (XDSS) 1
-24 AN742F13 I.. CLAMP 1
-25 2D26 1.. SWITCH 1
-26 2G16 I.. FILTER, Amber 2
-27 1 2G14 I.. FILTER, Green 1 2
-28 327 1.. LAMP 4
-29 2(=268 1.. HOUSING 1
-30 3691190118-41 SCREENASSEMBLY 1
*Notfurnished, but must be used:with engine automatic reignition equipment. Normally supplied with
engine; if not, must be separately procured.
1-3
Section 1 Opt Eqpt Manual CSP-005
_I
t
i
i 13
12 1 ,RELAY BRACKET
i
14
s
o
I O
11 c
7
i
I jii CENTER CONSOLE
t~,?
c
-.4 TB 502
.r(
TB 501
ORELAY INSTALLATION
RELAY IN STALLATION
22 I
j 21
19
18
~IE OLEO SUPPORT
9/5
j 20
8;18icB
3
5
17i 25
23 10
8 O
/e DIOOEISOLATOR
9
26
k,
7 ASSEMBLY
fa
25
i
O SWITCH INSTALLATION 24 2j
.h
!-?1
C,\
.:i I!
ai ill i
c
3Y-
ENGINE COMPARTMENT ./I =;r

I
II
8~
PIB
r i I
it
i
I~
(I~yi)L(%B
.J~" 1
47-221
Figure 1-2. Engine automatic reignition equipment (military configuration)
1-4
FIG. UNITS USABLE

NO. NO. ASSY CODE
1-2- 369B90118-515 AUTOMATIC ENGINE REIGNITION KIT I 1

-1* 1 IGNITIONEXCITER I 1
6870885
43754 IGNITION EXCITER (Interchangeable with.... 1
6870885)
6870891 1 IGNITION EXCITER (Interchangeable with. 1
6870885)
10-387150-1 1 IGNITION EXCITER (Interchangeable with.... 1
6870885)
-2* FHE161-9A I IGNITER 1
6843984 1 IGNITER (Interchangeable with FHE161-9A)... 1
6874271 1 IGNITER (Interchangeable with FHE161-9A)... 1
(YB63- 1)
3691190118-51 1 DIODE ISOLATORASSEMBLY 1
-3 MS20341-6C I.. NUT 1 2
-4 MS35338-136 1.. WASHER 2
-5 NAS620C6L I.. WASHER 1 4
-6 MS35275-229 1 SCREW. 2
-7 j AN316-4 NUT 2
-8 IN3210 i.. DIODE (CR1, CR2) 1 2
-9 1 BUS 1
369B90118-5
-10 3691190118-3 BRACKET 1
4
-11 MS2 1042L02 1 NUT
-12 WASHER 8
NAS620C2
-13 SCREW 4
MS35206-203
1 RELAY ASSEMBLY (K104) 1
3691190118-71
-14 RELAY 1
369B4243
1 with 3691-14243)..., 1
369A4557 RELAY (Interchangeable
1 RELAY ASSEMBLY (K304) 1
369B90118-91
-15 369B4243 1.. RELAY I 1
1
369B4557 1 RELAY (Interchangeable with 369B4243).
1
_16 M835059-222 1 SWITCH (S11).
NUT 1
-17 MS21042L08
2
-18 NAS620C8L I WASHER.............
1
-19 NAS602-7 I SCREW..............
SUPPORT 1
-20 369B90118- 17
SWITCH ASSEMBLY (XDSS) 1
369B90118-101
CLAMP 1
-21 AN742F13
SWITCH 1
-22 2D26
2
-23 2G16 FILTER, Amber........
2
-24 2G14 FILTER, Green
LAMP 4
-25 327
HOUSING 1
-26 2C268
SCREEN ASSEMBLY 1
-27 3691190118-41
with 369D294201-703 1
-28 A23DMM20T-1 I MODULE (Used
instrument panel)
Normally supplied with

*Not furnished, but must be used with engine automatic reignition equipment.
engine if not, must be separately procured.
1-5/1-6
CSP-OS 1
Opt Eqpt Manual Section 2
SECTIOM 2
MAINTENANCE INSTRUCTIONS
2-1, GENERAL INFORMATION. 2-5. OPERATIONAL CHECK.
2-2. DESCRIPTION. The engine automatic re- 2-6. Perform the following operational check
ignition equipment consists of a switch assembly procedure whenever it is necessary to verify that
(XDS9) placarded RE-IGN/ARMED, switch (S11) the system is operating properly:
placarded ARM-OFF, reignition relay assemblies a. Check that BATTERY switch is in OFF
(K104, K304), diode isolator assembly containing po~ition.
diodes CR1 and CR2, and miscellaneous wiring, b. Connect external electrical 28 vdc power to
hardware and splices that interconnect the fore- helicopter (section 2, HMI Vol 1).
going components and interface with existing heli- c. Place BATTERY switch in EXT position.
copter equipment (K301 start relay, CB106 cir- d. Close circuit breakers (refer to applicable
cult breaker, dimming unit (P12), engine power wiring diagram, figure 2-3 (commercial confi~u-
out warning control unit and the exciter). Loca- ration), or figures 2-4 and 2-5 (military
tions of the major components are shown in configurations)).
figures 2-1 and 2-2.
NOTE: Closing AUTO RE-IGN circuit breaker
2-3. OPERATION. The automatic

provides power to ARM-OFF switch
engine re-
ignition equipment provides a means to automati- e. Place ARM-OFF switch (S11) in ARM posi-
cally reignite the engine when either or both of tion; check that green ARMED portion of switch
the following conditions exist: (1) engine N1 (gas (XDSS) illuminates.
producer) speed (rpm) is less than 50 55 per-
NOTE: The green ARMED light may be dim or
cent; (2) NR (rotor) speed is less than approxi-
mately 460 rpm. The starting circuit for the bright depending on the dimming switch volt-
starter-generator (section 19, HMI- Vol 1) is age (14 or 28 volts). If the electronic dimming
isolated by automatic reignition circuit diodes circuitry is in the dim mode, and it is desired
to change to bright illumination, pull (open) and
(CR1, CR2). With circuit breakers (see applica-
reset (close) COMM PNL LTS (annunciator panel
ble wiring diagram fig, 2-3, 2-4, or 2-5) in
closed position, and ARM-OFF switch (S11) in lights) circuit breaker (CB104) (commercial
ARMED position, the lamps of the green ARMED helicopters and military helicopters with 369D
294201-703 instrument panel) or (CB123) (mili-
portion of switch assembly (XDSS) illuminate.
tary helicopterswith 369D294201-705 instru-
With the ARM-OFF switch at ARM, the ARMED
ment panel).
indicator of the XDSS switch assembly illumi-
nates. A flameoutcauses the engine power out f. Verify audible engine ignition.
warning control unit (section 17, HMI Vol 1) to
NOTE: With engine in a flameout condition,
energize R104 reignition relay, which then pro-
and ARM-OFF switch (S11) in ARM position,
vides 28 vdc to the exciter and fires the igniter.
a simultaneous signal from the engine power
Simultaneously, the RE-ION indicator of the
out warning control unit will energize the re-
XDSS switch assembly illuminates while the
ARMED indicator remains illuminated. When the ignition relay (K104) which provides continuous
28 vdc to the ignition exciter and fires the
RE-ION switch/indicator is depressed, the XDSS
switch assembly is reset and the RE-IGN indica- Spark igniter.
tor extinguishes.
g. Verify that switch (XDSS) RE-IGN indicator
lamps illuminate and that ARMED lamps remain
2-4. REFERENCE DATA. power out
Engine
illuminated.
warningcontroluriit: section 17, HMI- Vol 1.
h. Place ARM-OFF switch (S11) in OFF posi-
Start relay: section 19, HMI Vol 1.
Interfacing
tion; RE-ION and ARMED switch (XDSS) indicator
schematic and wiring diagram: section 20, HMI
Vol 1. lights should go off.
2-1
RELAY ASSEMBLY (K304) REIGNITION RELAY (K104)

(369H90118-91), (369H90118-711
HOUSING
LAMP (4)
//O o
j
DISPLAY
MODULE
i" "I
LEGEND
FACE
O LAMP ACCESS -IXDS9) SWItCH
INSTRUMENT PANEL STRUCTURE

BRACKET (369H2505-169)
LEFT SIDE
INSTRUMENT PANEL
(369H64161 (NOTE)
rSWITCH ASSEMBLY
(XDS9)
CLAMP
SUPPORT
EDGELIGHTED
ARM-OFF
PANEL (NOTE)
O
SWITCH
II Illli I II /II ASH
TRAY
O INSTRUMENT PANEL FACE

LOOKING DOWN INSTRUMENT PANEL FACE
LOOKING FORWARD
WIRE BUNDLE
(NOTE)
WIRE BUNDLE
:iii
FWD DIODE ISOLATOR
ASSEMBLY (CR1, CR2) RIGHT OLEO SUPPORT
P303 ~ylilll I I FITTING (NOTE~
START RELAY
(K301) (NOTE)
LOWER RING
SECTION (NOTE)
SP17 SP18
NOTE:
STATION
PART OF HELICDPTER.
137.5
ENGINE AREA RIGHT SIDE
47-013A
Figure 2-1. Major component locations (commercial configuration)
2-2
RELAY (K304) 1 IJSWTCH ASSEMBLY

IXDS91
,REIGNITION
RELAY (K104)
CLAMP
SUPPORT
q
::I
RELAY
BRACKET SWITCHARM-OFF
TB502 IS11)
TB501 O AUTO RtlGNITION

GNIKO LSEHCTIWS
DOWN
CENTER CONSOLE
RIGHT SIDE
HOUSING
roa
*la LAMP (41
d
~ulo Il-IGWIIIO*
j DISPLAY
MODULE
INSTRUMENT PANEL FACE

INSTRUMENT PANEL FACE (3690294201-705) LEGEND FACE
13690294201-703)
O LAMP
INSTRUMENT PANEL FACE

LOOKING FORWARD
WIRE BUNDLE
(NO
WIRE BUNDLE
FWD DIODE ISOLATOR

ASSEMBLY (CR1. CR2) \RICHTOLEOSUPPORT
pJ03 ~1/11( 1 I FITTING (NOTEI
START RELAY
(K301) INOTE)
LOWER RING
SECTION(NOTE)
SP17 SP18
NOTE:
STATION
PART OF HEL I CO PTER. 137.5
ENGINE AREA RIGHT SIDE
41-223
Figure 2-2. Major component locations (military configuration)
2-3
Section 2 Opt Eqpt Manual CSP-OOJ
i. Press switch (XDSS) RE-IGN indicator to a. InstrurnentPanel.

reset switch. (1) Examine ARM-OFF circuit breaker
j. Deenergize electrical system as follows: and RE-IGN/ARMED indicator/switch assembly
(1) Open circuit breakers. for damage and security of attachment to
(2) Place BATTERY switchinOFF position. panel.
(3) Disconnect external electrical power. (2) Examine reignition relay for damage
2-7.
andsecurity of attachment to bracket.
TROUBLESHOOTING.
(3) Examine wiring for damage; wire ter-
2-8. Use information in table 2-1 in
conjunction minals for security of attachment.
with the wiring diaArani for troubleshooting. The b. Engine Area.
troublesllootinR table presunies good indicator
lamps. Whenever a trouble symptom includes or (1) Examine diode isolator assembly for
consists of failure of an indicator to be illumi- damage and security of attachment.
nated. verify lamp condition by substituting a
(2) Examine wires and splices for damage;
lamp known to be good before proceeding with wire terminals for security of attachment.
troubleshooting.
2-9. REMOVAL AND INSTALLATION. 2-13. WIRING DIAGRAMS.
2-10. For installation of components, refer to

section 3. For removal, reverse procedures. 2-14. Figures 2-3, 2-4, and 2-5 are wiring dia-
grams for the engine automatic reignition equip-
2-11. INSPECTION.
ment and show interconnections with the helicopter
2-12. Insl,ect the engine automatic reignition electrical system and associated instrument panel
equil,nlent as follows: caution and wiring indicating equipment.
Table 2-1. Troubleshooting engine automatic reignition equipment
Symptom Probable Trouble Corrective Action
System functions normally, Defective lamp Replace lamp

except RE-IGN switch/
indicator does not illuminate. Defective switch (XDSS) Replace switch (XDSS)
assembly, assembly.
RE-lGN switch/indicator Defective diode (CR1) Replace diode or diode

illuminates during normal isolator assembly.
(non-automatic) starting.
System fails to function with Defective reignition Replace reignition relay

28 vdc present at terminals relay (K104). (K104).
D and E of TB502-13 and
ARMED i~ldicator is illuminated.
ARMED indicator is not illumi- Defective ARM-OFF Replace switch (S11).

nated and system fails to func- switch (S11).
tion with 28 vdc at terminals D
and E of TR502-13.
ARMED indicator illuminated, Defective diode (CR1). Replace diode or diode

RE-IGN switchjindicator isolator assembly.
illuminated, 28 vdc present at
connector 1 of CR1, but less
than 26 vdc present at con-
nector 2 of CR1 (of diode

isolator assembly). Automatic
reigllitioil fails to occur.
Engine starter energizes Defective diode (CR2) Replace diode or diode

when ARM-OFF switch is at isolator assembly.
ARM, engine is shut down,
and power applied to bus.
2-4
CSP-003 Opt Epqt Manual Section 2
JIP9 TB1-6 JIP113

53 r-\ r\
(rc~--K51OA20 --I 8 r -K51a20- -I A K510D20 -1 B C -PlllD20- 1
1 2
B
LCI 5106
r-----------Kso2C20----------------i D t- K502GM -i A P112A20 --I

L-J
I_,-1
TB502-ll
!/-P,9 iA~--------J503D20
r------------ D c--J503E20--1 B
r,E, J
r--
PUSH TO RESET
T
NC RE-IGN
S2_C I
J501BM
NO 1 1
C~ ~r-E567A22 I I I NC
C) (0
20 GA JUMPER S1_C~ 2
2\\ 2
1 IIPLACES~ I r" .NO
L531A22 ARM
B) [A
Sil
.I IP--01
J50 JHHAMN
1 3 J502A207 ARMED
XDSB
SWITCH ASSEMBLY
E2
J502E20 JS02D20
4 6
8 LJ508AMN 1 7
J507AA20 1 2,1+
K304
20GAJUMPER
P12
r\
loJ
4 PLACES
CB11)4
COMM
3
1
K104
3
45
1
1 -\20GA JUMPER
2 PLACES
E559An
XDSIII
LNPC-l~
B~11-1 LTS
21+
JM9A20N E2 T8502-13 P19
r---~
i I
~E559ACn D c---J507A20-----1 U
GEN OUT lo~- E i
L----l
r----------
JIP303
SP18 CR1 SP17 r----~
L~- 2
-I
.T3-1
-JWC20- K502D20 MC-Pllal8- EXCITOR
I,J L-----l
K301
r---~
1T~
C i KM2CA20 I~
I I j CR2
ENGINE AREA
IX1V I DIODE ISOLATOR ASSEMBLY
L-t--~
L__ __ _ _ -C
.I
Is-~l Norrs:
i. FOR ADDITIONAL INFORMATION, REFER TO SECTION 17, HMI-VOL 1.

2. 50LI0 LINES INDICATE WIRES SUPPLIED WITH MUIPMWT.
3. DASHED LINES INDICATE WIRING OR ITEM OF HELICOPTER

ELECTRICAL SYSTEM (SECTION 19, HMI-VOL 1). 47-0121\
Figure 2-3. Wiring diagram (commercial configuration)
2-5
ENG 781-6 JIP112

START I
JIP616 A L--K510BZ0---I B c-- PlllD20--,
0"-2__ KSOBA20--~ A lr--K~OBAA20------------: B
I ~I
~S106
r -1
csla
K502C20 --------------1
lcl
D ~--K50ZB20--, A
j r-Pf12A20--~
t-----------------------------
L_J I_,-1
78502-13
JIP9 JIP618 r A ~------J503D20
r-\ r--
i c------ J501AD20----------i B i
r----
IJ503EE20
i
cslw I PUSH TOR[StT

1.-~2,-- E567AZ2
r-o
oc---JSOUM-------~1 J501B20
1 52 CIjNC RE-IGN
NO I
1
LVIILIURYI) __
__
Il NC
C) [O
Ci 2 2
PIJ616 i I 20CAJUMPER I I 2
2
8 PLACES
r---J501AB20_____,~ INO
ARM B1 (A
JIP618 S11
nOlAcm--~ ARMED
3 1 I I I/ XDSP
J50
SWITCH ASSEMBLY
Json20 J502020
8 J508A2(XJ
K304 2d,
5 1 I""""" I Y4
Z0GAJUMPER r i \-I I I 1 3
4 PLACES ~I i I
1 I I I
~-r, I I I I I K104 I i 5
~ZOCAJUMPER
PPLACES
I celo4 PI; I I J5WA20U TBI02-U PI

i r-, I
o ~------i J ID L---JS07A20----i U I
1~8102-10 ANN PNL LTS
F
A E559AB22-------~ D
XDSII ~-I-
3----~
B --c( GEN OUT I
L-----J
C E559AC22
IC~-__ (MILITARY*)
I i i --JIP30) I
I i I SP18 CRI SP17 r
1 2
I M EXCITOR
I L------~
K301
CAP:
-t-
I 1 2
-.I=
L-------K502C20--I X2X1 CR2
DIODE ISOLATOR ASSEMBLY

I
I START RELAY
ENGINE AREA
~E13:
L
NOTES:
I. FOR ADDITIONAL INFORMATION. REFER TO SECTION 17. HMI VOL 1. +MILITARY WITH 3690294201-703 INSTRUMENT PANEL CONFIGURATION
2. SOLI D LINES i-I INDICATE WIRES SUPPLIED WITH EPUI PMENT.
3. DASHED LINES I----) INDICATE WIRING OH I ItM OF HELICOPTER

ELECTR ICAL SY STEM (SECTION 19. HMI VOL 11. 47-227
Figure 2-4. Wiring diagram (standard military configuration)
2-6
CSP-005 ODt Eqpt Manual S(!c:tir,n 2
781-6 1112 P112

ENG
r-,
J616 P616
START IA ~-KSIOB20-; 18;--PlllD20--,
rr-
1 o K508A20 A -K508AA20------ B C~,,,,
CB 125 ICI
------KMZC2O D KSOIB?O-I A
J
78502-11
P9 J9 JblB Pb18
T~
rA~--J503D20
i c------~lolno?o---- --------------(BI
r----- ;D~ c--lsolnnza-
J503EE20 LC!
I CB105
P616 J616
r-E567A22- J618 P618
2 PUSH To RESET
bL J501A20 J501AB20
52 NC
IMILITARY*) C1 RE-IGN
J501B20 NO
r-- C) (0
51 NC
ARM ZOGAJUMPER I Ci 2P~2
2 2
511
INO
J502A20 B) (A
1 3
J501AE20
J505A20N ----t~q -I IARMED
XDSP
I I SWITCH ASSEMBLY
4 Y6
J502E20--o~ J502D20 P7
78502-13
7
iSOBA2W r~F----JS07AZO--
I
EI C/1
4J507AA20
3
20 GA
2PLACES JUMPERIN"HICI1" I
5
11(104 POSITION
MIST-CAUTION
DS119
Pb17 J617 P526 r7
6
ANN PNL LTS 2NO T~ cl
D I U 28 VDC (IN)
8 cela P616 J616 ~-b
8 K304 t
1
-o
2
H T-CIIC
6 If
5
20 GA JUMPER
-1 G I i C I C -I 1 14 VDC (IN)
cs 124 c,Cr I
4PLACES
1 C~C) I
INSTL LTS IND-CAUTION
3 L -j
DS118
_ _ _ _ _
4
E17A22 c~l P527 r
E559AC22 Al
21t
CE
(MILITARY
~i-- SP18 SP17

1
CR1
II I
J 5038 20
1 2 r-T-
M~ P112F18 -s;XCITDR 7p-,
K502CA20K502CB20--~- -K502DM
JS03CM
L------J
K301 LIJ
GAP3
r 4
;-------KrozC2a-------t -.1.-
X2 CR2
DIODE ISOLATOR ASSEMBLY

ill~j
i NOTES:
ISTART RELAY
ENGINEAREA
I. FOH ADDITIONAL INFORMATION. REFER TO SECTION 17. HMI VOL 1. "IV\ILITARY WITH 3690294201-705 INSTRUMENT PANEL CONFIGURATION
2. SOLI D LINES I--) INDICATE 1YIRES SUPPLIED Cj ITH EOUI PhlENT.
3. DASI1ED LINES INDICATE \\IIRING OK I:ihl OF HELICUPTEK

ELECTR ICAL SYSTEM ISECTION 19. HMI VOL i). 47-299
Figure 2-5. Wiring dia~ram (SLAE military configuration)
2-7 2-8
SECTION 3
INITIAL MODIFICATION (INSTALLATION)
INSTRUCTIONS
3-1. GENERAL INFORMATION. wiring to existing harnesses until all electrical
wiring and components are installed.
3-2. SCOPE. This section provides instructions
for installation of the engine automatic reignition a. Remove nut and washer securing forward
equipment. These instructions cover removal or end of K301 start relay to 369A2537 oleo
support.
modification of existing equipment to accommo- b. Clean area for electrical
bonding around
date reignition equipment. large hole in bracket (10, fig. 1-1 or 1-2) and that
portion of K301 start relay bracket exposed by
3-3. REFERENCE DATA. Where directed in the removal of nut and washer in step a, above.
following procedures, refer to the Handbook of c. Using nut and washer remove~d in step a,
Maintenance Instructions, Volume 1 (HMI Vol 1) above, install diode isolator assembly so tha~ lug-
and to the Optional Equipment Manual (Opt Eqpt type diode connectors are aft.
Manual) for the Standard Liff]lt Avionics Equip- d. Locate wire 5503(320 (open end) in harness
ment (SLAE) for supplementary information and running vertically, just forward of station 135.5
procedures. Refer to table 3-1 for a list of con- bulkhead and approximately 6 inches aft of diode
sumable materials and expendable items used isolator assembly (fig. 2-3, 2-4, or 2-5). Place
during initial installation. Items listed are com- a 2.5-inch length of silicone tubing (9, table 3-1)
mercially available and may be obtained locally, on wire for use in step f, below.
Equivalent items and materials are acceptable. e. Connect wire 5503B20 from diode CR1 of
diode isolator assembly to the B-end of knife
3-4. PREPARATION FOR INSTALLATION. splice SP18 (11). Connect A-end of
same splice
to wire 5503C20 located in step d, above.

3-5. Preparing for installation of engine auto- f. Slide silicone tubing (9) over SP18 splice
mntic reignition equipment includes the following: and secure with tie-strap (2) at each end of splice.
a. Place BAT-OFF-EXT switch in OFF g. Remove
existing wire K502D20 from termi-
position, nalX2 of K301 start relay. Cut off existing ter-
b. Open engine right access door (section 2, minal, remove and save existing terminal protec-
HMI Vol 1). tor, slip 2.5-inch length of silicone tubing (9) on
c. Identify allcompon~nts, including attaching wire, and connect wire to B-end of knife splice
hardware, removed to gain access to work areas. SP17 (11).
Protect components from damage and contamina- Connect A-end of SP17 splice to K502CB20
h.
tion until installed. wire from common connector 2 of CR1 and CR2
diodes of diode isolator assembly,

3-6. INSTALLATION OF ENGINE AUTOMATIC i. Slide silicone tubing oyer splice and secure
REIGNITION SYSTEM. with tie-strap (2) at each of SP17

splice.
el-~
j. Place terminal proteqiir removed in step g,

NOTE: The engine automatic reignition kits above, on wire K502CA20of diode isolator assem-
are supplied with as many parts assembled bly. Connect wire to X2 terminal of K301 start
as practical, however, some parts may re- relay and slide terminal protector into place.
quire assembly at installation. The follow- k. Secure wiring with string (4) as required,
ing paragraphs provide complete assembly making certain that sufficient wire slack remains
instructions. The operator should omit so that connectors are not stressed.
those steps which may have already been i. After assembly and test apply insulation
accomplished. varnish (3) to exposed threads and tips of diodes
CR1 and CR2.
3-7. DIODEISOLATOR ASSEMBLY. m. Close engine access door.
NOTE: When providing ground for electrical 3-8. RELAY AND SWITCH ASSEMBLY (COM-
components, clean contacting surfaces to bare MERICAL CONFIGURATION).
metal (section 19, HMI Vol I). Do not a. Remove instrument panel left and right side
tighten electrical clamps or secure electrical covers to expose lightening holes (HMI Vol 1).
3-1
Section 3 OPt Eqpt Manual CSP-003
Table 3-1. Consumable materials and expendable items
Commercial Product
Item
No. Material Specification Name/No, Manufacturer
1 Solder SN60WRP2 As required Commercially

(Q&-S-561) available
2 Strap, tiedown MS3367 Size as Commercially

required available
3 Varnish. insulation Glyptal General Electric

No. 1201 InsulationDept.
Schenectady. NY
4 String. lacing T-3333 General Cable Corp.

Los Angeles. CA
5 Wire. white No. 47108B General Cable Corp.

AWG as Los Angeles, CA
required
6 Wire. white MIL-W-16878/4 As required Commercially

type (alternate for
E available
General Cable Corp
No. 147108B
7 Wire, bus MIL-W-3861/5 AWG 20? soft Commercially

drawn- as available
required
8 Insulation sleeving, electrical MIL-I-631, type F? Size as Commercially

(vinyl shrink tubing) form U, Grade A, required available
Class 1, Category 1
9 Insulation sleeving, electrical Variglass, Commercially

CL. H-A-1, available
No. 2-as
required
10 Insulation sleeving, electrical MIL-L-3190 Size as Commercially

(fiberglass) (alternate for Vari- required available
glass CL. H-A-I)
11 Splice, knife MS25181-1 As required Commercially

available
12 Terminal, wire MS25036- 102 As required Commercially

available
13 Terminal, wire MS25036-149 As required Commercially

available
14 Pin. contact MPCMP0M-HB As required Commercially

available
15 Decal 36 911901 18- 27 Hughes Helicopters

16 Decal 3691190118-33 Hughes Helicopters
17 I)ecal 36 9H901 18- 35 Hughes Helicopters
18 Decal 369B90118-37 Hughes Helicopters
3-2
b. Remove ash tray and edge lighted panel (7) Iioute wire 5502320 from relay (K304)
from lower switch and circuit breaker panel. (15, fig. 1-1) and connect to contact 4 of ARM-
c. Remove screws and loosen lower switch OFF switch (S11).
ana circuit breaker panel. (8)
Arrange relay wires to form smooth
d. Remove and discard square cutout and adja- flow integrating with existing wire bundles: use
cent round hole button covers located above tie-straps (2, table 3-1) as required to secure
PRESS TO RESET placard. wire bundles. Ensure sufficient wire slack to
e. On left side of instrument
panel structure, avoid stress on solder joints.
install relay K104 (14, fig. 1-1) in center posi- (9) If bracket (18, fig. 1-1) has been re-
tion, and relay K304 (15) in aft position, on brack- moved for installation ease, clean bracket/panel
et (18) with screws (13), washers (12), and nuts contact areas to ensure positive ground; install
(11). bracket (18) with screws (16)
(17). and washers
(10) Route ground wire J505A20M from
NOTE: Bracket (18) is installed in upper half switch (XDSS) coil housing (29) and cn;lnect to
of largest lightening hole in left side structure ground stud E2.
of instrument panel. (11) Route wire 5502D20 from RE-IGN/
ARMED switch (XDSS) (29) and connect to contact
f. Clean area around ARM-OFF switch (S11) 6 of ARM-OFF switch (S11).
(19~ mounting hole in lower switch and circuit (12) Route wire 5503D20 from switch (XDSS)
breaker panel, to prepare bonding surface for (25) and insert pin in contact A of TB502-13.
switch support (23); clean all surfaces around (13) Route wire 5501B20 from switch (XDSS)
holes in support (23). (25) and insert pin in contact A of ARM-OFF
g. Insert threaded shank of ARM-OFF switch switch (S11).
(19~ through half-inch hole in support (23) followed i. Install instrument panel left side cover
by key washer with washer tang toward switch (HMI Vol 1).
actuator arm. m. Clean screw attach areas of lower switch
h. Insert ARM-OFF switch (19) through half- an;i-circuit breacker panel to ensure positive
inch mounting hole in lower switch and circuit grounding bond; install panel.
breaker panel; install washer and nut making cer- n. Install edge-lighted panel and ash tray on
rain tang is positioned in small hole adjacent to lower switch and circuit breaker panel.
half-inch hole in panel, o. Perform operational check of engine auto-
i. portion of cylindrical (coil) housing
Clean matic reignition electrical system in accordance
(29~ to contact clamp (24); insert switch assembly with paragraph 2-5.
(XDSS), from front side of panel, into square cut-
out mounting hole in lower switch and circuit 3-9. RELAY AND SWITCH ASSEMBLY (MILI-
breaker panel. TA
j. Secure housing (29) of switch (XDSS) to sup- a. Remove console right side cover (HMI
port (23) with clamp (24), screw (22), washers Vo~ 1).
(21), and nut (20). b. Remove additional panels as required to
k. Install electrical wiring as follows: facilitate installation of engine automatic reigni-
(1) Route wire 5502A20 from relay K104 tion switches and wiring.
(14) to ARM-OFF switch (16) and connect to con- c. Remove ARM-OFF and RE-ION/ARMED
tact 3 of switch (S11). switch hole covers panel.
from instrument
(2) Route wire J503EE20 from relay K104 d. relay bracket (for relays K104 and
Locate
(14) and insert pin in contact C of terminal block K304) (14 and 15, fig. 1-2) on right side of con-
502, module 13 (TB502-13). sole inner panel.
(3) Route wire J508A20N from relay K104 e. Install relays K104 and K304 (14 and 15) as
(14) and connect to ground stud E2. follows:

(4) Route wire J507AA20 from relay K104 (1) Install relay K104 (14) in outboard posi-
(14) and insert pin in contact E of TB502-13. tion, and relay K304 (15) in inboard position, on
(5) Route wire E559AC22 from relay K304 relay bracket, with screws (13), washers (12),
(15) to closest proximity of GEN/OUT wire and nuts (11).
E559A22; connect wires E559AC22 and E559A22 (2)
Arrange relay wires to form a smooth
with splice (11, table 3-1). flow, integrating with existing wire bundles; use
Route wire J501AE20 from relay K304
(6) tie-straps (2, table 3-1) as required to secure
(15, fig. 1-1) to contact 1 of ARM-OFF switch wire bundles. Ensure,sufficient wire slack to
(S11) (19); install terminal (12, table 3-1) on wire avoid stress on solder joints.
J501A20; connect terminals of wires J501AE20 f. Install ARM-OFF switch (S11) (16, ig. 1-2),
and J501A20 to contact 1 of ARM-OFF switch an~ RE-ION/ARMED switch assembly (21 thru 27),
(S11), Route wire J501A20, install terminal as follows:
(13) and connect to contact 2 of circuit breaker (1) Clean area around ARM-OFF (S11)
106 (CR106). switch hole in instrument panel to prepare bonding
3-3
surface for switch (XDSS) support (20, fia. 1-2): (7) Route wire J501AE20 from relay K304
install (AUTO RE-IGNITION) decaL (15, table 3-1). (15, fig. 1-2), and connect to contact 1 of ARM-
clean all surfaces around holes in support (20, OFF switch (S11) (16),
fi~. 1-2). (8) Route wire 5502320 and connect to con-
(2) Insert threaded shank of ARM-OFF tact 4 of ARM-OFF switch (S11),
switch (S11) (16) through half-inch mounting hole (9) Route ground wire J505A20N from switch
in support (20) followed by key washer with washer (XDSS) (26) and connect terminal to ground stud
tanfi toward switch actuator arm. E31.
(3) Insert ARM-OFF switch (S11) (16) (10) Route wire 5502D20 from switch (XDSS)
through half-inch mounting hole in instrument (26) and connect terminal to contact 6 of ARM-
panel: install washer and nut making certain key OFF switch (S11),
washer tang is in small hole adjacent to half-inch (11) Route wire 5503D20 from switch (XDS9)
hole in panel. (22) and insert pin in contact A of TB502-13.
(4) clean portion of cylindrical (coil) hous- (12) Route wire J501B20 from switch (XDS9)
ing (26) to contact clamp (21): insert switch as- (22) and connect to contact 3 of ARM-OFF switch
sembly (XDSS) into square cutout mounting hole (S11).
in instrument panel. (13)
Relocate wire J501A20 as follows:
(5) Secure housing (26) of switch (XDS9) to On aircraft equipped with 369D
(a)
support (20) with clamp (21), screw (19), washers 294201-703 instrument panel, disconnect wire
(18), and nut (17). J501A20 from CB124 on circuit breaker panel,
g. Install electrical wiring as follows: and connect to contact 2 of CB106,
Route wire J502A20 from relay K104
(1) (b) On aircraft equipped with 369D
(14) to ARM-OFF switch (S11) (16) and connect to 294201-705 instrument panel, disconnect wire
contact 3 of ARM-OFF switch (S11). J501A20 from CB119 on circuit breaker panel,
(2) Route wire J503EE20 from relay K104 and connect to contact 2 of CB105.
(14)and insert pin in contact C of terminal block h, Install black cover decals (17 and 18, table
502, module 13 (TB502-13). 3-T) over AUTO RE-IGN markings of previously
(3) Route wire J508A20N from relay K104 used circuit breaker position on edge lighted cir-
(14) and connect to ground stud E31. cult breaker panel; install new AUTO RE-ICN
Route wire J507AA20 and insert pin in
(4) decal(l8), see figure 3-1.
contact E of TB502-13. i. Install console right cover.
(5) On aircraft equipped with 369D294201- Secure all panels loosened or removed for
703 instrument panel, install wire E559AC22 as access.
follows: k. Perform operational check of engine auto-

(a) Install module No. 20 (28) on ma~tic reignition system in accordance with para-
TB502. graph 2-5.
(b) Route wire E559AC22 from relay
K304 (15) to TB502 and insert pin in contact C of 3-10. WEIGHT AND BALANCE.
TB502-20.
(c) Install pin (14, table 3-1) on wire 3-11. Weight and balance changes resulting from
E559AB22; insert pin in contact A of TB502-20 installation of engine automatic reignition equip-
and route wire to plug P12. Crimp pin on oppo- ment are listed in table 3-2. After installation of
site end of wire E559AB22 and insert pin in con- the engine automatic reignition system equipment,
tact D of P12. incorporate changes in helicopter weight and bal-
(d) Install pin (14) on wire E559AA22: ance record as instructed in HMI Vol 2.
insert pin in contact B of TB502-20. Route oppo-
site end of wire E559AA22 to GEN OUT (XDS18)
Table 3-2. Weight and balance data
warning light and solder (1) to contact 3.
(6) On aircraft equipped with 369D294201-
Weight Arm Moment
705 instrument panel, install wire E559AC22 as
follows:
(Ib) tin. tin. -lb/100)
(a) Route wire E559AC22 to closest Added 1.5 41.5 1.4
proximity of wire E17A22 (routed between P526-
EE and P527-A). 0. 0
Removed 0.0 0.0
(b) Cut wire E17A22; install 2.5-inch
length of silicone tubing (9) and splice (11) wires 91.5 +1.4
Change +1.5
E559AC22 and E17A22. Slide tubing over splice
and secure with tie-straps (2).
3-4
AVTO-IGN
HEAT TRIM ENG INST
oooa~o
DE-ICE
N2 CYCLIC START OUT
GOV
O CB106
CARGO
CIRCUIT BREAKER
PAN~L 169H9214~
HOOK LTR
O rGYRDS
LIGHTS
I
ATT DIR LDG ANN
O!~QQ MOVER PANEL
COVER EXISTING MARKINGS

WITH BLACK DECALS
CBID5
a
TRIM ENG ENC INST
VER EXISTING IIIARKINGS
0000 00 WITH BLACK DECALS
CYCLIC START OUT ICN;

N2
CIRCUIT BREAKER
GOV AUTO RE-IGN
PANEL 3690294566 O ADD AUTO RE-IGN DECAL
XPDR ADF ICS VHF UHF VHF
000000
FM AM AM
O
LIGHTS
TOW ANN INST
CB124
MOVER PANEL
CB123
47-300
Figure 3-1. Circuit breaker panel decal installation (military configurations)
3-5/3-6
CSP
008
Publication No.lCSP-008
Illusfrated Parts List

and
with Initial Installation Instructions

FOR
ATTITUDE GYRO INDICATOR

Part No. 3691190033-501
USED ON HUGHES 500D (MODEL 369D) HELICOPTERS
E) nushes Helicopters
COD671040 Issued 1 August 1976

IVI FG I
INTRO
RECORD OF REVISIONS
CSP-008
MFG REV
NO DESCRIPTION ISSUEDATE ATPREVDA INSERTED BY
TEMP ATP REV INSERT DATE REV REMOVE

CSP-OOB Opt Eggt Manual Table of Contents
ATTITUDE GYRO INDICATER
TABLE OF CONTENTS
Section Page
FOREWORD .F-~
F-r. Purpose and Content of this

Manual P-]
Optional Equipment F-l
F-4. Organization ofContents F-]
F-5. Use oIthisManu;a~ F-I.
F-6. Related Publications F-l
F-7. Literature Changes and
Revisions ......F-~
1 ILLUSTRATED PARTS LIST 1-1
I-I. Scope and Contents 1-I

1-2. Group Assembly Parts
1-1
1-3. Illustrations ..........]-1
2 MAINTENANCE INSTRUCTIONS 1: 2-1
2-1. Generallnformation ..2-1
Section Page
2 MAINTENANCE INSTRUCTIONS
(CONT)
2-2. Maintenance of Attitude

Gyrolndicator .........2-4
2-3. Replacement of Attitude
GyroIndicator .........2-4
3 INSTALLATION INSTRUCTIONS 3-1
3-1. GeneralInformation ....3-1

3-2. ReferenceI)ata .........3-1
3-3. Preparation ...........3-1
3-4. Removal of Instrument....
Panel Equipment....... .3-3
3-5. Modification of Instrument
Panel
3-6. Installation of Attitude Gyro
Indicator
3-7. Completion oflnstallation ..3-6
3-8. Weighta\dBalance ......3-6
3-9. General
CSP- 008 Opt Eqpt Manual For eword
FOREWORD
F-l.PURPOSE AND CONTENT OF THIS organized to provide comprehensive coverage of

MANUAL. This manual supplements information entire systems, major equipment groupings, and
contained in HMI- Vol 1 and 369D IPC, and major components that are similar or associated.
contains instructions for initial installation and Procedures for each of these are presented in
maintenance for the R. C. Alien 102- sequence as defined in Section I, HMI Vol 1.
continuing
0045-01 artifical horizon gyro indicator, also
known as the attitude gyro indicator. Weight and F-5. USE OF THIS MANUAL. This manual is
balance data is included. This manual also con- for useby operators of the Model 369D helicopter
tains parts lists for procuring replacement parts equipped with attitude gyro indicator. Although
this manual is a separate publication, it should be
for the attitude gyro indicator installation.
kept with HMI Vol i, HMI Vol 2, 369D IPC
F-2. APPLICABILITY. The attitude gyroindi- and other handbooks listed in Section I, HMI
cater isapplicable for use on any Hughes 500D Vol 1 that form the primary information file for
(Model 369D) helicopter, the helicopter.
F-3. COMPATIBILITY OF COMBINED F-6. RELATED PUBLICATIONS. Referenceis

OPTIONAL EQUIPMENT. compatibility
For
made to applicable portions of HMI Vol 1 and
information on which optional equipment may or 369D IPC as required to accomplish instructions
may not be used in combination at the same time, contained herein.
refer to Section 21, HMI- Vol 1.
F-4. ORGANIZATION OF CONTENTS. The con- F-7. LITERATURE CHANGES AND REVISIONS.
into sections Changes and revisions to contents of this manual
tents of this manual are grouped as
Each section is are made as defined in Section I, HMI Vol 1.

outlined in the Table of Contents.
F-I/F-2
SECTION I
1-1. SCOPE AND CONTENTS. This illustrated 1-2. GROUP ASSEMBLY PARTS LIST. The
parts list provides, by means of text (parts lists) parts lists furnish information for procuring re-
and companion illustrations, a complete parts placement parts for the attitude gyro indicator
definition of the 3691190033-501 Attitude Gyro installation and shall not be used for any other
Indicator Installation, manufactured by Hughes purpose.
1-3. ILLUSTRATIONS. An isometric illustration
NOTE: The illustrated parts list is organized is for the group assembly parts list.
provided
and presented in the same manner as the 369D The illustration is exploded to the extent necessary
Series Illustrated Parts List (369D IPC). to show parts relationship for the complete attitude
(For information on use, refer to 369D IPC.) gyro indicator installation.
1-1
Section Opt Eqpt Manual CSP- 008
i i
C--:II1I:III:l?::_ ._~.li11111117111_
~i
nii
jj
3:
I IiIUI
i I
i i
I
i ill~; O
ii Ijy.~
ii1 ii
i
i
,j I 1
i it
8 ~h \Px
i j
I
i
~cn:
O INSTRUMENT
INSTRUMENT
PANEL
ii
8
or
~s
a
i
I
I
,/~h w
si O sr
i
Q CIRCUITBREAKER- INSTALLATION
I
I i
I i
7
14\
13
12
11-\"4B"~ \t\ I
o 10
i~7i
GM
L,J i- Is
.I
d
"al I;I
rl
.:o
20
sa p
II
I
f
1 I
I
ATTITUDE O TERMINAL BOARD
BOARO INSTALLATION
GYRO- INSTALLATION
47-035
Figure 1-1. Attitude gyro indicator installation
1-2
CSP-008
UNITS
FIG.
DESCRIPTION PER
INDEX I PART
ASSY
NO. NO.
ATTITUDE GYRO INDICATORINSTL REF

1-1- 369H90038-501
SCREW 3
-1 MS35214-26
WASHER 3
-2 AN960PD6L
NUT 2
-2 MS21043-3
I SCREW 2
-3 NAS1635-3-7
AN960C10L WASHER 2
-4
369H6455-41 STRAP ASSY 1
-5
(Not used when optional 369B90039 directional gyro
indicator is installed)
369116455-21 1 CLAMP ASSY. 1
-6
369B92831 INDICATOR ATTITUDE CYRO.............. 1
-7
(R. C. Alien 10210045-01 artificial horizon gyro
indicator- modified)
2TC13-5 CIRCUIT BREAKER 1
-8
3691190038-3 HARNESS ASSY. 1
-9
MS2 1083C08 NUT 1
-10
LOCKWASHER 1
-11 MS35338-42
NUT 1
-12 NAS671-8
WASHER 3
-13 AN960C8L
SCREW 1
-14 NAS1096-2-10
NUT 2
-15 MS21043-04
WASHER 4
-16 AN960PD4L
SCREW 2
-17 NAS1635-04-7 i..............
2
-18 MS21083C06 I NUT
I WASHER 4
,19 AN960C6L
NUT 2
-20 NAS671C6L
TERMINAL BOARD 1
-21 MS27212-1-2 1
1-3/1-4
SECTION II
2-1. GENERAL INFORMATION. The attitude NOTE: To eliminate possibility of electrical

gyro indicator is an all-electric gyro indicator interference with KR 85 ADF equipment
with a pictorial horizon and rotating dial that con- installed, a noise filter is included as part
tinuously indicates helicopter pitch and roll com- of the ADF option. (For more information
pared to pitch and roll references established by on the filterinstallation, refer to the appli-
an internal gyro. The indicator is mounted upper cable ADF Opt Eqpt Manual.
center in the instrument panel (fig. 2-1). The
instrument provides attitude indication by means
of a horizon bar, turn index mark and the outline 2-2. MAINTENANCE OF ATTITUDE GYRO
of an airplane. Attitude indication results from
INDICATOR. Maintain the gyro indicator as in-
internal gyro reactance to a corresponding pitch
structed in Section 17, HMI Vol 1, except re-
and roll attitude of the helicopter. Slip indication
is by means of a conventional ball and tube at the
place according to paragraph 2-3.
lower front of the instrument face. The instru-
ment requires and uses 28 vdc electrical power
from the GYROS circuit breaker CB105. The 2-3. REPLACEMENT OF ATTITUDE GYRQ
gyro is caged by use of a knob at lower right of IND~CATOR. (See figure 2-1.)
instrument. A knob at the lower center of the a. Check that all electrical power is OFF.
instrument allows aligning the airplane outline b. Remove instrument panel hood and left and
with the horizon bar when the helicopter is in right fairings (Section 17, HMI Vol 1).
level flight permits pilot selection of desired
and c. Remove screws from front cf indicator.
pitch A knob at lower right
attitude reference. Disconnect electrical connector from back of in-
is for erecting the gyro. Figure 2-2 provides a dicator. Remove clamp, then remove indicator.
wiring diagram for the installation and an internal Installreplacement indicator in reverse
schematic for the indicator. order to removal.
2-1
ATTITUDE GYRO :w~

INDICATOR ~ln i
;sEl~i
u,
Osz
DIRECTIONAL GYRO
INDICATOR
(NOTE 1) a~a
il:X
/C;~ ?3 J
1~::
I
z ..y/
;f-9-
R
:L~
ELECTICAL
/Vi
PLUG P506
ATlITUDE CYRO
INDI CATOR
INSTRUMENT
J
PANEL FACE
:d:
UPPER SUPPORT
ASSEMBLY
t~l
h.~-- NOTES:
i. OPTIONAL EQU IPMENT. (REFER TO

STRAP
(NOTE 2) OPTIONAL EQU I PMENT MANUAL.)
2. STRAP IS NOT USED WHEN
r
DIRECTIONAL GYRO
O A~ITUDE CYRO INDICATOR SIROTACIDNI
INSTALLED.
47-040
Figure 2-1. Attitude gyro indicator replacement

2-2
MOTOR
EREC- OFF
TION INDICA-
SYSTEM TOR
GYRO INTERNAL SCHEMATIC
INVERTER
C A B D
+28 VDC COMMON

SPARE
GYROS
CB105 P506
1 ~2 1
O u----~---FsolA20 RED C
5A ATTITUDE
SPARE A
GYRO
,~,F501R20N(NOTE 2)4
P506W10 BLU --I D INDICATOR
MP 501
GROUND SPARE B
TB103 JUMPER
W3 TB6
E26
+28 VDC BUS WITHOUT NOI SE FILTER
t--- F501A20 -tO L I NE

RED--~---(
CND
i F501R20N BLU-----4
I v,
NOISE FILTER LOAD

nloo--
INOTE 5)
WITH NOISE FILTER (NOTE 4)
WIRING DIAGRAM
NOTES:
i. THIS WIRING DIAGRAM SHOULD BE USED WITH ELECTRICAL

SYSTEM WIRING DIAGRAM IN HMI-VOL 1 FOR COMPLETE
CIRCUIT IDENTIFICATION.
2. DASHED LINE ITEMS ARE PART OF HELICOPTER BASIC

ELECTRICAL SYSTEM.
3. TERMINAL NUMBERS ARE FOR REFERENCE ONLY AND MAY NOT

BE ON COMPONENTS.
4. ELECTR ICAL NOISE FILTER IS USED IN STEAD OF TB 103,

IF KING KR 85 ADF EPUIPMENT IS INSTALLED.
5. CASE ELECTRICALLY BONDED TO STRUCTURE (SECTION 19,

HM I-VOL i).
47-038
Figure 2-2. Wiring and schematic diagrams attitude gyro
2-3/2-4
SECTION III
INSTALLATION INSTRUCTIONS
3-1. GENERALINFORMATION. Proceduresin recommended items and are of a commercial

this section may be performed at operators dis- nature that should be procurable locally. Alter-
cretion and provide complete instructions for nate, but equivalent, items are acceptable.
initial installation of the attitude gyro indicator.
Information in the installation instructions is pre- 3-3. Preparationfor installa-
sented as additional procedures to those for main- tion indicator includes the
tenance of standard instruments in HMI Vol 1. following:
(Reference is made in instructions to applicable a. Identify all components, including attaching
data in HMI Vol 1 to accomplish installation of hardware, or components removed for access to
the attitude gyro indicator. work areas. Protect components from damage
and foreign matter until installed.
3-2. REFERENCE DATA. Table 3-1 lists con- b. Check that all electrical switches are OFF.
items required
for the installation. Itemslisted in the consum- NOTE: Make sure that BATT-OFF-EXT
able materials and expendable items table are switch is OFF.
Table 3-1. Consumable materials and expendable items.
Material Specification Commercial Product

Item
No. Name/No. Manufacturer
No.
EP711 or Pro- Coast Pro-Seal

1 Compound sealant
Seal 247 Compton, CA
369116615- 161 Hughes HeM-

2 Decal
copter,
Culver City, CA
3 Decal 369B6615-163 Hughes
4 Terminal MS25036-101
6 Terminal MS2 5036- 149
7 Grommet MS212 66- 1
TC112 Thomas and Betts Co.

8 Tie strap base
Elizabeth, NJ
9 Tie strap, nylon ~idS11821- 1-9
10 Washer AN960C6L
11 Rivet MS20470M4
.12 strip
369116455-19 Hughes
3-1
3-4. REMOVAL OF INSTRUMENT PANEL NOTE: Strap (5) is not used if directional gyro
EQUIPMENT. indicator is installed.Apply strip (12, table

a. Remove instrument panel hood and left and 3-1) using sealant compound (1) in place of
rig~ht instrument panel side fairings (Section 17, strap (5, fig. I-i).
HMI- Vo)l.)
b. Remove blank panel from upper center of
g. Attach harness assembly (9) to attitude gyro
ins~trument panel between airspeed indicator and
indicator(l). Secure harness assembly toinstru-
altimeter. Retain washers for reuse.
ment panel structure at existing tooling holes
using tie strap base (8, table 3-1), washers (10),

3-5. MODIFICATION OF INSTRUMENT PANEL.
nylon tie straps (9) and rivets (11) as required.
Prior to installing the attitude gyro indicator, It Protect harness assembly from chafing using
is necessary to modify cutouts in instrument
grommet (7).
panel structure and instrument panel hood. Make
modifications as shown in figure 3-1.
3-7. COMPLETION OF INSTALLATION.
3-6. INSTALLATION OF ATTITUDE GYRO a. Check entire installation for completeness.
b. Check all electrical wiring.
a. Locate and drill mounting holes for terminal c. Clean all foreign material from instrument
board and ground stud as shown in figure 3-2. panel.
b. board(21, figure 1-1)
Install terminal d. Reinstall instrument panel left and right
usihg screws (17), washers (16) and nuts (15). faiFing and hood (Section 17, HMI Vol I).
Install nuts (18, 20) and washers (19) on terminal e. Perform operational check of completed
board (21). attitude gyro indicator installation.
c. Install screw(l4), washers (11, 13) and f. Revise weight and balance records
nuts (10, 12). (para 3-8).
d. Apply decals (2, 3 table 3-1) at locations
shown in figure 3-2. 3-8. WEIGHT AND BALANCE.
e.Install circuitbreaker (8, fig. 101). Attach
harness assembly (9) to circuit breaker(8), ter-
minal board(21), and screw (14) using terminals 3-9. GENERAL. Weight and balance changes
(4, 5, 6 table 3-1) shown in figure 2-3.

as resulting from installation of the attitude gyro are
f. Install attitude gyro indicator (7) using clamp listed in table 3-2. After installation of attitude
(6); strap(5), screws (3), washers (4), nuts (2) gyro, incorporate changes in helicopter weight
and screws (1). and balance records as instructed in HMI- Vol 2.
Weight Arm Moment

(Ib) tin.) tin. lb/100)
Added 2. 8 43. 0 1. 2
Remove O. 0 0. 0
Changed +2.8 43.0 +1.2
3-2
CSP,OOB Opt Eqpt Manual SectionS
1.24
1. 24~ 0. 22 RADIUS
INSTRUMENT PANEL HOOD
0~0
o I~
OUT
XM8N XMSN
~3
(IEN
OUT CHIPS
M/R
XMSN
B
XMSN
FUEL
LOW
FUEL PRE8S
TO
O
O /-----7 O
M) 1.24
1.24-~-1 \0.22RADIUS
INSTRUMENT PANEL
47-037
Figure 3-1. Instrument panel-modification
3-3
C21 0. 168 -0.

AHOLE
ID571
0.75 1
_---(i~BEAD 7
70103 0.87
~1 t
i. 1Q
0. 112 0. 118 DIA HOLE

(2 PCACESI
Q
i-1 PITOT TUBE
INSTRUMMT PANEL LOWER ~UPPORT

(LOOKING AFTI
41-039
Figure 3-2. Terminal board-installation
3-4
CSP
009

and
Nlaintenance Inskuctions
with Initial installation Instructions
FOR
DIRECTIONAi GYRO INDICATOR
Part No. 3691190039-501 and 369B90039-503
USED ON HUGHES S00D AND 500H (MODEL 3891) AND 369H HELICOPTERS)

PREVl~jUS ISSUES OF THIS PUBLICATION
Hughes
COD051778 Reissued 15 June 1978

IVI FG I
INTRO
Opt EQpt Manual CSP-000
~Nltll L*JCLI CHANOLD ~ACES, DLIIIOY ~UrLIIEDCD rAGEI.

LIST OF EAEC~IVE PAGES OWrcrD. *DDID. O.I)ltIl(. sY TWT NRRENT CH~NOL.
Pa~ Reissue
Title 15June 78
Athru B 15June 78
C Blank 15June 78
i............................ 15June78
ii flank 15Sune 78
F-l 15 June 78
F-2 Blank. 15 June 78
l-lthru 1-3 15June 78
1-4 Blank.:. 15 June 78
2-1 thru 2-3 15 June 78
2-4 Blank 15 June 78
3-1thru3-3 15June 78
3-4 Blank 15 June 78
A Reissued 15 June 1978

CSP-000 Opt Eqpt Manual
HUGHES HELICOPTERS TECHNICAL MANUAL RECOMMENDED CHANGE REPORT
This manual has been prepared and distributed by the Commercial Service Publications Department
and is intended for use by personnel responsible for the maintenance of Hughes Helicopters. Periodic
revision of this manual will be made to incorporate the latest information. If, in the opinion of the
revisions.
Hughes Helicopters
Attention: J. J.Dillon, Commercial Service Publications

2/T7B
Originator
Address
Book Identification: Date:
Issue Date Revision No.
Figure Number(s)
nemarks/necommendations
B/C
Reissued 15 June 1978
RECORD OF REVISIONS
CSP-009
MFG REV
NO DESCRIPTION ISSUE DATE ATP REV DATEI INSERTED BY

1"
CSP-OOg Opt Eqpt Manual Table of Contents
DIRECTIONAL GYRO INDICATOR
TABLE OF CONTENTS
Section Page
FOREWORD F-l
F-l. Purpose and Content of

this Manual F-l
Optional Equipment..... F-l
F-7. Organization of Contents F-l
F-9. Use of This Manual F-l
F-ll. Related Publications..... F-l
F-13. Literature Changesand
Revisions F-l
1-1. Scope and~Contents 1-1

List 1-1
1-5. Illustrations 1-1
1-7. Usable on Code 1-1
2 MAINTENANCE INSTRUCTIONS1, 2-1
2-1. General Information 2-1

2-4. Description 2-1
2-6. Troubleshooting 2-1
2-8. Removal of Directional
Gyro Indicator........ 2-1
2-12. Installation of Directional
GyroIndicator 2-2
2-16. Wiring Diagram. 2-2
3 INSTALLATION INSTRUCTIONS

3-4. Preparation for
Installation 3-1
3-6. Removal of Equipment.:.. 3-2
3-8. Modification of Equipment 3-2
3-10. Installation of Directional
Gyro Indicator........ 3-2
3-12. Installation of Removed
Equipment. 3-2
3-15. Weightand Balance 3-2
Reissued 15 June 1978 i/ii

CSP-009 Opt Eqpt Manual Forward
FORMIORD
F-l. PURPOSE AND CONTENTS OF THIS Each section is organized to provide comprehen-
tained in HMI Vol 1 and 3691) and 369B IPC, presented in sequence as defined in section 1,
and contains instructions for initial installation HMI Vol 1.
and continuing maintenance for the directional
gyro indicator. Weight and balance data is F-9. USE OF THIS MANUAL.
included. This manual also contains parts list
for procuring replacement parts for the direc-
F-10. This manual is for use by operators of
tional gyro indicator.
the Model 369D and 369B helicopter equipped with
the directional gyro indicator. Although this
F-3. APPLICABILITY.
manual is a separate publication, it should be kept
F-4. The directional gyro indicator is applicable
with HMI Vol 1, HMI Vo12, 369D and 369B
for use on any Hughes 500D and 500H (Model 369D

IPC and other handbooks listed in section 1, HMI
Vol 1 that form the primary information file for
and 369H) helicopter.
the helicopter.

OPTIONAL EQUIPMENT. F-ll. RELATED PUBLICATIONS.
F-6. Forcompatibility information on which F-12. Reference is made to applicable portions

optional equipment may or may not be used in of HMI Vol 1 and 369D and 369B IPC as re-
combination at the same time, refer to section quired to accomplish instructions contained herein.
21, HMI- Vol 1.

F-8. The contents of this manual are grouped F-14. Changes and revisions to contents of this
into sections as outlined in the Table of Contents. manual are made as defined in section 1, Vol 1.
Reissued 15 June 1978 F- 1/F-i

CSP-009 Opt Eqpt Manual Section I
SECTION 1
1-1. SCOPE AND CONTENTS. to the extent necessary to show parts relation-
ship for the complete directional gyro indicator
1-2. This illustrated parts list provides, by installation.
means of text (parts lists) and companion illus-
trations, a complete parts definition of the 1-7. USABLE ON CODE.
369B90039-501 and 369H90039-503 Directional
Gyro Indicator Installation, manufactured by
Hughes Helicopters, Culver City, California. 1-8. The USABLE OM CODE column located at
the right-hand side of the Group Assembly Parts
NOTE: The illustrated parts list is organixed
List pages indicates the effectivity of parts by
and presented in the same manner as the 369D In many two
aircraft serialnumber. cases
Series Illustrated Parts List (369D and 369B
different parts are representing the
listed, one
IPC). (For information on use, refer to 369D installation and another representing an
original
and 369B IPC.
improved replacement item. Alphabetic codes
1-3. GROUP ASSEMBLY PARTS LIST. are used to indicate the aircraft serial number
applications of a given part. When no USABLE
1-4. The parts lists furnish information for pro- ON CODE islisted, items are understood to have
curing replacement parts for the directional gyro full effectivity.
indicator, and shall not be used for any other
USABLE ON AIRCRAFT
purpose.
CODE LETTER EFFECTIVITY
1-5. ILLUSTRATIONS.
A 3D thru subsequent
1-6. Illustrations are provided for each group
B 411H thru subsequent
assembly parts list. Each illustration is exploded
1-1
Reissued 15 J~ine 1978
Manual
CSP-009
Section 1 Opt Eqpt
j
i i
5
8;
i
ii ii i I~ 1
I
34 (I 1. I:
I
:3
I
Q,= r I
i\
7
13 a~\ 1
b-
P.
I uii i
i:Ti- i
I
i
12 6
o iI I
11 14 O -I
i i
9oi
18 II 9
csi
a
I 25
10 c~ p 28
4 J i
O 19
3-~t
r:
27
\i20 j C;~
33
25 26-3
j-..
n
24$;k
i
29i
30
8
i~ 1,,I 33
30
j
jj ?i 3122 23
23 32
j:: 21 O
47-058A
/i
i /i
L_
Figure 1-~. Directional gyro indicator installation

1-2
CSP-O00 Opt Eqpt Manual Section 1
UNITS USABLE
FIG.
DESCRIPTION PER ON
INDEX PART
ASSY CODE
NO. I NO.
1-1- 369B9OO39-501 DIRECTIONAL GYRO INDICATOR I(TT I 1 A

INSTALLATION
369B90039-503 DIRECTIONAL GYRO INDICATOR KIT I 1 B
INSTALLATION (Field Installation)
-1 NAS1635-3-7 I SCREW 2
-2 AN960C10L WASHER 2
-3 MS21O43-3 1 NUT 2
-4 369B6455-21 CLAMP ASSY I 1
-5 369B6455-15 STRIP A/R

-6 369B6455-19 1 STRIP A/R
-7 369B6455-41 1 STRAP ASSY 1
1
-8 MS35214-26 SCREW 3
-9 AN960PD6L WASHER 1 3
-10 369B92832 INDICATOR, DIRECTIONAL GYRO 1
-11 MS20470AD3 RIVET A/R B
-12 MS20470A4 RIVET A/R B
NAS1635-3-7 SCREW 2 B
-13
AN960C10L I WASHER 2 B
-14
-15 MS2 1043-3 1 NUT 2 B
369B6455-11 1 SUPPORT ASSY 1 B

-16
1 B
-17 369B4220-1 1 BRACKET
369H4220-2 BRACKET 1 B
-18
369B6615-161 DECAL I 1
-19
DECAL 1
-20 369B6615- 163 1
NAS671C6L NUT 2
-21
I NUT 2
-22 MS2 1083 CO6
AN960C6L I WASHER I 4
-23
NAS671-8 I NUT 1
-24
AN960C8L WASHER 4
-25 CIl
NUT........;.... 1
-26 MS2 1083C08
1
-27 111835338-42 WASHER, LOCK......,..=
I SCREW 1
-28 NAS1O96-2-10
SCREW............. 2
-29 NAS1635 -04-7 1..
4
-30 AN960PD4 L I WASHER
NUT................ 2
-31 MS2 1043 -04
1
-32 MS27212-1-2 TERMINAL BOARD, (TB1OJJ.;
1
-33 2TC13-5 CIRCUIT BREAKER, (CB1O5)
1
-34 369B9OO39-3 1 WIRE HARNESSASSY i I....
June 1978
1-3/1-4
Reissued 15
SEC~IOM 2
I\IIAINTENANCE INSTRUCTIONS
2-1. GENERAL MFORMATION. Table 2-2. Troubleshooting directional gyro

indicator
2-2. SCOPE, This section provides description
and maintenance information for the directional
Symptom Probable trouble Corrective Action
gyro indicator. This information is intended for
user-level (field) and service and repair.
Off indica- Disconnected elec- Reconnect
2-3. REFERENCEDATA. Wheredirectedin tion with trical wiring, electrical
the following procedures, refer to the Handbook system wire.
of Maintenance Instructions (HMI Vol 1) and to energized.
the publication listed in table 2-1 for trouble-
Defective electri- Repair or
shooting and repair of components beyond the
cal wiring. replace
scope of this manual. electrical
wire.
Table 2-1. Reference documents Disconnected or Connect or
defected system replace cir-
Source Document title circuit breaker. cult breaker,

as required.
R. C. Alien, Inc. Overhaul manual with Off and/or Heading indicator Replace
Instrument Div. Illustrated Parts List incorrect. defective. heading
Grand Rapids, Mich. Electrical Directional indicator.
49501 Gyroscope Indicator,
RCA15B, Publication
2-8. REMOVAL OF DIRECTIONAL GYRO
1318 INDICATOR.
2-4. DESCRIPTION. 2-9. Removal of the directional gyro indicator

is accomplished by the following operations;
(refer to fig. 2-1).
2-5. The directional gyro indicator is a gasket Insure that all electrical power is OFF.
a.
sealed, direct reading instrument which pro- b.Remove instrument panel hood and left and
vides a visualdisplay of helicopter heading, right fairings. Refer to section 17, HMI Vol 1.
For other leading particulars refer to manufac- c. Remove attachinghardware. Remove
turers document (table 2-1). clamp assembly, disconnect wire harness plug
(P507) and remove directional gyro indicator.
2-6. TROUBLESHOOT~G. d. Disconnect terminals from terminal board
(T-~103) and ground screw (E28) by removing
2-7. Refer to table 2-2 for troubleshooting infor- attaching hardware.
mation. This information is provided to aid in e. Remove terminal board (TB103) and ground
isolation faults found during operational check screw (E28) by removing attaching hardware.
on normal operation of system. The fault is 2-10. RE PAIR.

then removed by repair or replacement to return
the system to trouble free operation. For 2-11. Repair of directional gyro indicator is
troubleshooting and repair of internalcomponents limited to replacement of defective or damaged
of the directional gyro indicator beyond the scope parts as follows:
of this manual refer to reference documents a. Replace damaged or frayed wiring and
(table 2-1). terminals.
Reissued 15 June 1978 2-1

b. Replacedefective circuitbreaker (33, fig. e. Install directional gyro indicator (10, fig.
1-~ and terminal board (34). 1-~, clamp assy (4) using screws (1 and 8),
c. Replace defective directional gyro indica- washers (2 and 9) and, nuts (3).
tor (10). f. Install instrument panel hood and left and
right fairing. Refer to section 17, HMI Vol 1.
2-12. INSTALLATION OF DIRECTIONAL GYRO
INDICATOR.
2-14. INSPECTION.
2-13. Installation of directional gyro indicator

is accomplished by the following operations; 2-15. Inspect components of directional gyro
(refer to fig. 1-1). indicator in accordance with the following:
a. (TB103) (32) using
Install termal board a. Inspect wire harness (34, fig. 1-1) and
screws (29), washers (30) and nuts (31). wire terminals at circuit breaker (33) and ter-
b. Install ground screws (28) using washer minal board (34) for proper connection.
(25j and nut (26). b. Inspect clamp assembly (4) and directional
c. Install circuit breaker (CB105) (33) on gyro indicator (10) for proper installation.
instrument panel.
d. Attach wire harness (34) and terminals
2-16. WIRING DIAGRAM.
(2;-3 and 4, table 3-1), to terminal board (34,
fig. 1-1), circuit breaker (33) and ground screw
(28) using nuts (21, 22 and 24) and washers (23 2-17. See fig. 2-2 for the directional gyro
and 25) (refer to fig. 2-2). indicator wiring diagram.
2-2 Reissued 15 June 1978

ATTITUDE GYRO INDICATOR ii

OJOTE)
:I~i
STRAP ASSEMBLY
(NOTE)
i!
iii8
DIRECTIONALGYRO
INDICA1OR
I
::r(4ii\iI
iii ii
CLAMP ASSEMBLY
a pi
ELECTRICAL PLUG
(P507)
a
-r.
cr
DIRECTIONAL GYRO
...i~zi
INDICATOR ~:6 1
I
NOfE:
CIRCUIT BREAKER
STRAP ASSEMBLY IS NOT USED WHEN
i$j
OPTIONAL ATTI TU DE GYRO I N D I CATOR
ISINSTAL1ED,
(CB105)
Qql
47-056A
Figure 9-i, Directional gyro indicator replacement
GYROS
P507
CB105
1
F50 P501P22
Dc
X)
54 DIRECTIONAL
GYRO
INDICATOR
2
F501R2aU F501422
P506V16
GROUND TB103
BUS E26
TB6
CB103
P506W 10
i~ 02
+28 VDC
BUS
NOTES:
i, THIS WIRING DIAGRAM SHOULD BE USED WITH ELECTRICAL

SYSTEM WIRING DIAGRAM IN HMI-VOL 1 FOR COMPLETE
CIRCUIT IDENTIFICATION.
2, DASHED LINE I----) ITEMS ARE PART OF HELICOPTER BASIC

ELECTRICAL SYSTEM,
3. TERMINAL NUMBERS ARE FOR REFERENCE ONLY AND MAY NOT

BE ON COMPONENTS,
4, CASE ELECTRICALLY BONDED TO STRUCTURE (SECTION 19,

HMI-VOL i),
47-057/1
Figure 2-2, Wiring diagram directional gyro indicator installation
Reissued 15 June 1978 2-3/2-4

SECTION 3
3-1. GENERAL INFORMATION. recommended items and are of a commercial

nature that should be procurable locally. Alter-
3-2. SCOPE. Procedures in this section may be nate, but equivalent, items are acceptable.
discretion and provide
complete instructions for initial installation of 3-4. PREPARATION FOR I~STALLATION.
the directional gyro indicator system. Informa-
tion in the installation instructions is presented 3-5. Preparation for installation of the direc-
as additional procedures to those for maintenance tional gyro indicator system includes the
of standard instruments in HMI Vol 1. Refer- following.
ence is made in instructions to applicable data a. Identify all components, including attach-
in HMI Vol 1 to accomplish installation of the ing hardware, or components removed for access
directional gyro indicator. to work areas. Protect components from damage
and foreign matter until installed.
b. Check all cockpit electrical switches for
3-3. REFERENCE DATA. Table 3-1 lists con-
OFF condition.
expendable items required
for the installation. Items listed in the consum- NOTE: Make sure that BATT-OFF-EXT
able materials and expendable items table are switch is OFF.
(2)
Commercial Product
Item
[1) Manufacturer
No. Material Specification No. Name/No.
EP711 or Coast Pro-Seal

1 Compound sealant
Pro-Seal 247 Compton, California
MIL-S-750L PR1221 Product Research
Burbank, California
5 Grommet MS21266-1
TC112 Thomas and Betts Co.

6 Tie strap base
N.J.
Elizabeth,
7 Tie strap, nylon MS17821-1-9 (3)

8 Washer AN960C6L
9 Rivet MS20470A4
The prefix symbols defined as

NOTES: (1) Numbers are U. S. A. Specifications and Standards. are
follows: AMS American Material Standard; MS Military

Military Standard; MIL
triple alpha prefix of the same letter Federal Speci-
Specification; Single, double, or
Air Force-Navy Aeronautical Standard; NAS National Aerospace Standard.

fication; AN
Any equivalent material may be used as an alternate selection.
(2) Primary selection.
materials of
(3) Use the best comparable grade material when the conformity of available
determined.
the same type with the listed Specification No. cannot be
3-1
3-6. REMOVAL OF EQUIPMENT. (28) using nut (21 and 22), washers (23) and
washer (25) and nut (24).
3-7. Prior to installation of the directional gyro f. Apply decals (19 and 20) as shown in fig.
indicator the following items must be removed: 1-1.
a. Remove instrument panel hood and left and ff. Position brackets (17 and 18) and support
right instrument panel fairings. Refer to section assembly (16) on instrument panel and install
17, HMI Vol 1. using rivets (11 and 12) as required. Install
b. Remove attaching hardware for blank panel screw (13), washer (14) and nut (15).
located in upper center of instrument panel. h. Install directional grro indicator (10) using
Retain washers foruse in installation of direc- screw (8), and washer (9). Install strap assem-
tional gyro indicator. bly (7), strip (5 and 6) as required. Install
clamp assembly (4) using screw (1), washer (2)
NOTE: On 500H (model 369B) helicopters and nut (3).
removal of one or both center windshield
panels may be required. NOTE: Strap assembly (7) is not used if
optional attitude gyro indicator is installed.
3-8. MODIFICATION OF EQUIPMENT. ApplJ strip (6) using sealant compound (1,
table 3-1) in place of strap assembly (7).
3-9. Prior to installation of the directional gyro
indicator the following modifications must be i. Attach wire harness (P507) to directional
preformed: gyro indicator at (5507) location.
a. Locate and drill two .112/. 116 diameter
holes for mounting terminal board (TB103), 3-12. INSTALLATION OF REMOVED EQUIP-
(view A, fig. 3-1). MENT.
b. Locate and drill one .168/. 175 diameter
hole for mounting of ground screw (E26), (view 3-13. After installation of directional gyro indi-
A, fig. 3-1). cater, following equipment must be reinstalled.
the
c. Locate angles and rework as shown in view a. panel hood and left and
Reinstall instrument
B, figure 3-1. right instrument panelfairings. Refer to section
17, HMI- Vol 1.
NOTE: If the attitude gyro is installed rework b. Reinstall center windshield panels as
~f the angles may not be required, required.
d. On 50011 (model 36911) helicopters the 3-14. COMPLETION OF ~STALLATION.

following modification to the instrument panel a.Inspect all attaching hardware to ensure
structure may be required components are secured.

(1) Locate existing stiffener as shown in b. Check all electrical wire to ensure correct
view C, figure 3-1, and drill out attaching rivets attachment.
as required. c. Clean all foreign material from instrument
panel and areas around terminal board installation.
3-10. INSTALLATION OF DIRECTIONAL GYRO
INDICATOR. 3-15. WEIGHT AND BALANCE.
3-11. Refer to figure 1-1 and preform the 3-16 Weight and balance data changes that result
following: from installation of directional gyro are listed
Position wire harness assembly (34) on
a. in Table 3-2. After installation of directional
insi~rument panel structure at existing tooling gyro, incorporate changes to helicopter weight
holes. Secure wire harness assembly to instru- and balance record as instructed in HMI Vol 2.
ment panel using tie strap base (4, table 3-1),
washers (6) nylon tie strap (5) and rivets (7) as
required. Table 3-2. Weight and balance data

b. Install circuit breaker (CB105) (33, fig.
Weight A1m Moment
Position terminal board (TB103) (32) and
c.
(Ib) tin. tin. -lb/100)
in~tall using screws (29), washers (30) and nuts
(31). Added 3.1 43.0 1.3
d. Install screw (28) using washer (27) and
nut (26).
Attach wire harness (34) and terminals Removed 0.0 0.0
e.
(2,-3 and 4, table 3-1) to terminal board (TB103)

(32, fig. 1-i), circuit breaker (33), and screw Changed +3.1 43.0 +1. 3
3-2 Reissued 15 June 1978

;e 2. 62--,
_-1
1.31
ANGLE
1 J
0. 12 RADIUS MAXIMUM
i PANEL ITYPICAL)
o MODIFICATION OF ANGLES
~kl
O, 1M(
DIAMETER HOLE
-i~" 0.175
n75~111 ~__
i) G
BE~O
o. llf DIAMETER HOLE I 1 I ~1. 19

0. 116 (2 PLACES)
f BEAD
i. 50
PITOT TUBE
O GROUN_D
TER_MINAL BOARD AND
STUD MODIFICATION
I 1~CLAMP ASSEMBLY
STRIP
SYMMETRY ABOUT
CENTERLINE
L~BRACE
1,-- s -~-a
~QI :1000
O
O O
ROOi
O
i\l
II U
11I SCREW, WASHER, NUT
(2 PLACES)
SCREW, WASHER, NUT
(2 PLACES)
Q FIELD INSTALLATIO~I MODIFICATION 47-055A
Figure 3-1. Directional gyro indicator modification
Reissued 15 June 1978 3-3/3 -4

CSP
0~0
Illustrated Parts list

and
with Initiarl Instarllation Instrvctions

FOR
INSTANTANEOUS VERTICAL SPEED INDICATOR (IVSI)

Part No. 3691190044
USED ON HUGHES 500HS (MODEL 369HS) AND 500D (MODEL 3690) HELICOPTERS
AND
Part No. 3691190044-503
USED ON HUGHES 500E AND 530F (MODEL 369E/F) HELICOPTERS

Hughes Helicopters, Inc. Culver City. California 90230

A Subsidiary of McDonnell Douglas
COD020185 Reissued 01 February 1985

IVI FG,
INTRO
C~t Eqpt I~ianual CSP-010
INSERT LATEST CHANCED PACES. DtST)Or SUPERSEDED PACES.

LIST Of EFFECTIVE PAGES THE ASTERISK INDICATES PAGES CHANGED. ADDED. OR DELETED BY THE CURRENT CHANGE.
Page Date
Title Original
A thru B..... Original
CBlank Original
i....... Original
ii Blank Original
F-l Original
F-2 Blank.............. Original
1-1 thru 1-5............ Original
1-6 Blank.............. Original
A Reissued 01 February 1985

Opt Eqpt Manual
use
revisions.
Hughes Helicopters
Attention: R.M. Impens, Commercial Service Publications

6/A141
Originator
Address
Issue Bate Revision No.
Figure Number(s)
nemarks/Recommendations
Reissued 01 February 1985 B/C

RECORD OF REVISIQNS
CSP-010
MFG REV
DESCRIPTION ISSUE DATE DATE BY REMOVED INCOR BY

REV NO
CSP-010 Opt Eqpt Manual Table olContents
TABLE OF CONTENTS
Section Page
FOREWORD F-l
F-l. Purpose and content of

this Manual.......... F-l
F-3. Compatibility of. Combined
Optional Equipment...... F-l
F-5. Use of this Manual....... F-l
F-6. Related Publications....... F-l
Revisions.......... F-l
1-I. Scope and Contents....... 1-1

List 1-1
2-1. GeneralInformation 2-1

2-3. ReferenceData 2-1
Reissued 01 February 1985

Table of Contents
Opt Eqpt Manual
CSP-010
TABLE OF CONTENTS
Section Page
2-5. Maintenance of Vertical

Speed Indicator......... 2-1
2-6. Replacement of Vertical
Speed Indicator- Model
369HS and 369D
Helicopter 2-1
2-7. Replacement of Vertical
369E/F Helicopters 2-1
3 INSTALLATION INSTRUCTIONS.. 3-1

3-2. Preparation 3-1
3-3. Removal of Instrument
Panel Equipment........ 3-1
3-4. Installation of Vertical
369HS and 369D
Helicopters 3-1
3-5. Installation of Vertical
Speed Indicator and Bolt
Light- Model 369E/F
Helicopters 3-1
3-6. Completion of Installation 3-1
3-7. Weight and Balance 3-1
3-8. General 3-1

CSP-010 Opt Eqpt Manual Foreword
FOREWORD
F-l, PURPOSE AND CONTENT OF THIS outlined in the Table of Contents. Each section
MANUAL. This manual supplements information is organized to provide comprehensive coverage
contained in the Basic Handbook of Maintenance of entire systems, major equipment groupings
Instructions (HMI Vol 1) and the nlustrated and major components that are similar or
Parts Catalog (IPC), and contains instructions associated, Procedures for each of these are
continuing~ maintenance
for initial installation and presented in sequence as defined in Section 1,
for the instantaneous vertical speed indicator. HMI Vol i.
Weight and balance data is included, This manual
also contains parts lists for procuring replacement F-5. USE OF THIS MANUAL. This manual is
parts for the instantaneous vertical speed indicator. for use by operators of the Model 369EIS and 369D/
E /F helicopters equipped with the instantaneous
F-2. APPLIC~. The 369B90044 instan- vertical speed indicator. Althoufh this manual
taneous vertical speed indicator (nVSI) is applica- is a separate publication, it should be kept with
ble for use on any Hughes 500HS (Model 369HS) HMI Vol 1, HMI Vol 2, the IPC and other
and 500D (Model 369D) helicopter. The 369H90044- handhooks listed in Section i, HMI Vol 1
503 IVSI is applicable for use on any Hufhes 500E that form the primary information file for the
(Model 3693) and 530F (Model 369F) helicopter. helicopter.
F-3. COMPATIBILITY OF COMBINED OPTIONAL F-6. RELATED PUBLICATIONS. Reference is

E&UIPMENT. Forcompatibility inforination on made to applicable portions of HMI Vol 1 and
which optional equipment may or may not be used the IPC as required to accomplish instructions
in combination at the same time, refer to contained herein.

Section 21, HMI Vol 1,
F-4. ORGANIZATION OF CONTENTS. The con- Changes and revisions to contents of this manual
tents of this manual are grouped into sections as are made as defined in Section i, HMI Vol I.
Reissued 01 February 1985 F-1/F-2

SECTION I
1-i. SCOPE AND CONTENTS. 1-5. ILLUSTRATIONS.
1-6. Isometric illustrations are provided for

1-2. This illustrated provides, by
parts list
each group assembly parts list. Each illustra-
tion is exploded to the extent necessary to show
trations, a complete parts definition of the instan-
parts relationship for the complete installation of
taneous vertical speed indicator system, manu-
the instantaneous vertical speed indicator.
factured by HuRhes Helicopters, Inc., Culver City,
California.
NOTE: The illustrated parts list is organ- 1-8. The USABLE ON CODE column located at
ized and presented in the same manner as the right-hand side of the Group Assembly Parts
the Illustrated Parts Catalog. (ZPC). (For List pages indicates the effectivity of parts by
information on refer to the IPC. aircraft serialnumber. In many cases two dif-
use,
ferent parts are representing the
listed, one
original installation and another representing an

1-3. GROUP ASSEMBLY PARTS LIST. improved replacement item. Alphabetic codes
are used to indicate the aircraft serial number
1-4. The parts list furnish information for pro- ON CODE is listed, items are understood to have
curing replacement parts for the instantaneous full eff ectivity.

vertical speed indicator installation and shall not
A 369E/F SN 0001 through subsequent
be used for any other purpose. For information
or procurement of other replacement parts, refer B 369HS S/N 411 through 874
to the appropriate IPC. 369D SN 0003 through 1204
Reissued 01 February 1985 1-1

I1
iu
S
i u
i~ii
i
,aij
AIRSPEED INDICATOR (REFI;jl~
~%a i:*
I
k" ~s
(REF)s,or4I)3li
ALTIIII1ETER
a
--~J
WASHERS- PART OF
BOLT LIGHT ASSEMBLY
(ADD AS RE4UIRED)
TO PITOT
TVBE
TO STATIC DRAIN
FILLING
O INDICATOR TUBING AND BOLT LIGHT INSTALLATION (ROTATED)
47-1190
Figure I-if Vertical Speed Indicator Installation and Holt Light 369E/F Helicopters
1-2 Reissued 01 February 1985

FIG. 8( UNITS USABLE
INDEX PART DESCRIPTION PER j ON

NO. NO. ASSY CODE
1-1- 369B90044-503 INSTANTANEOUS VERTICAL SPEED A

INDICATOR INSTALLATION
-1 NY400-1-OR I UNION 1 A
-2 7130 1 INDICATOR 1 A
-3 369B90044-43 1 TUBE 1 A
-4 369B90044-39 1 TUBE 1 A
-5 369H90044-37 1 TUBE 1 A
-6 NY400-3 I TEE 1 A
-7 AN935-8L I LOCKWASHER 1 A
-8 NAS620ABL I WASHER 1 A
-9 60336-1 1 TAB.............................. 1 A
-10 5952-8ND-CW-28 1 BOLT LIGHT 1 A

-11 MS35214 I SCREW 2 A
-12 M3 902 9/22 -20-2 O I CONTAC T 1 A
1-3
i 1
!I
;I:
I
ii!I
i
i
i i
i
"i r
;j
ii I! ii 1111-~ -111 i
i/i j
I,i
2
i
00
3
1i
60jj
13
15
0~/
;I
i
r ALTIMETER (REF)
AIR SPEED
INDICATOR (REFI
i :i
O INDICATOR MOUNTING
ROTATED i.
TO STATIC DRAIN 11
FITTING
9\io7 6
5
O INDICATOR TUBING
ROTATED 47-059A
Figure 1-2. Vertical Speed Indicator Installation 369HS and 369D Helicopters

CSP-010 Ol,t Eql,t Manual Section 1
FIG. r UNITS USABLE

NO. NO. ASSY CODE
1-2- 369B90044 INSTANTANEOUS VERTICAL SPEED 1 B

INDICATOR INSTALLATION
-1 NAS603-8 I SCREW 2 B
-2 AN960PD10L I WASHER 2 B
-3 369890044131 1 CLAMP ASSY 1 B
-4 3691190044-21 1 BRACKET ASSY 1 B
-5 3691-16612-3 1 TUBE 1 B
-6 NY400-3 I TEE 1 B
-7 36 91190044 17 1 TUBE 1 B
8 NY400-1-20R I CONNECTOR 1 B
-9 NY400-9 I UNION ELBOW 1 B
-10 NY401AOR I ADAPTOR 1 B
11 NY-(AND-4)-1- I REDUCER. 1 B
1/2-20
-12 AN6290-5 I O-RING 1 B
-13 MS33737-14 1 NUT.............................. 3 B
-14 MS35214-31 I SCREW 3 B
-15 SLZ9066 I INDICATOR 1 B

1-5/1-6
SECTION II
2-1. GENERALINFORMATION. Theinstanta- HMI Vol i, except replace indicator according

eous vertical speed indicator presents helicopter to paragrai,h 2-6 (369HS and 369D) or 2-7 (369E/F)
climb and dive information. Helicopter ascent herein.
is indicated by clockwise rotation of the pointer
from zero at the 9 oclock position. Descent is 2-6. REPLACEMENT OF VERTICAL SPEED
indicated by counterclockwise rotation. Internal INDICATOR MODEL 369HS AND 369D
stops prevent excessive pointer movement. Range HELICOPTERS. Replace vertical speed indicator
of indicator is O 3. 000 feet per minute, ascent as shown in figure 2-1 and as follows.
or descent. a. Check that all electrical power is OFF.
b. Remove instrument panel hood and left and
2-2. DESCRIPTION. Theinstantaneous vertical fairings (Section 17, HMI I).
Vol
speed indicator is a coupled inertial lead and c. Remove adapter, reducer and O-ring from
barometric pressure instrument that indicates rear of indicator. Remove clamp assembly,
the rate of
change in feet-per-minute due to mounting hardware and vertical speed indicator.
climb or dive maneuvers. A pendulum mass d. Install replacement indicator in reverse
~Yithin the instrument provides an instantaneous ortjer of removal.
reaction to change that is sustained by barometric
pressure. The instantaneous vertical speed 2-7. REPLACEMENT OF VERTICAL SPEED
indicator is mounted inside the instrument panel INDICATOR MODEL 369E/F HELICOPTERS.
directly below the altimeter (fig. 1-1 or fig. 1-2). Replace vertical speed indicator as shown in
A small slotted screw in the lower left face of figure 2-2 and as follows.
instrument provides for zero adjustment. a. Check that all electrical power is OFF.
b. Disconnect static line from rear of
2-3. REFERENCE DATA. Instrumentpanel vertical speed indicator.
andindicating systems: Section 17, HMI Vol 1. c. Remove plug, nut, lockwasher, washer,
Weight and balance data: HMI Vol 2. and tab from bolt light.
d. Remove bolt light from upper right corner
2-4. TROUBLESHOOTING. Useinformation of vertical speed indicator.

in table 2-1 for troubleshooting the vertical e. Remove two screws and remove vertical
speed indicator, speed indicator from instrument panel.
f. Remove union from rear of vertical speed
2-5. MAINTENANCE OF VERTICAL SPEED indicator.
INDICATOR. Maintain vertical speed indicator g. Install replacement indicator in reverse
as outlined for instruments in Section 17, order of removal.
Table 2-1. Troubleshooting Vertical Speed Indicator
Excessive lag in vertical Vertical speed indicator Replace vertical speed

speed indication. defective, indicator.
Erroneous vertical speed Disconnected or loose Reconnect or repair

indication (airspeed or static pressure line. static pressure line.
altimeter erratic).
Erroneous vertical speed Vertical speed indicator Replace vertical speed

indication (airspeed and defective. indicator.
altimeter correct).

CLAM P AS SEMBLY
ALTIMETER
BRACKET ASSEMBLY
AIRSPEED INDICATOR
i
Y
i;c
i
O-RliVG
$9 ~i
YERTICAL SPBO
VERTICAL SPtED w
INDICATOR
INDICATOR
ii:
i i
ALTERNATE LOCATIONS
NOTE: (NOTE)
IF VEATICAL SPEED INDICATOR IS

INSTALLED IN EITHER ALTERNATE
LOCATION, CLAMP ASSEMBLY AND
BRACKET ASSEMBLY ARE NOT USED. QoiJ
i.; O
47-050
Figure 2-1. Vertical Speed Indicator 369HS and 369D Helicopters Replacement
2-2
AIR SPEED :X
INDICATOR I~
~P
a;, ~il t r
VERTICAL I~_\PYB
i
ALTIIII\ETER
SPEED
~i
i
c
~3
B
d
i i
BOLT LIGHT"e
^j;a~bi.7 i
I
s
.DTa
VERTICAL 5 PEED I ND I CATOR
UNION
0//
LOCKWASHER
SCREW
Ic
PLUG
--5 NUT
3
ii pTAB
WASHERS
WASHER
(NOTE)
BOLT LIGHT
NOTE:
ADDED AS REUUIRED TO UP DIFFERANCE

IN PANEL THICKNESS.
47-1191
Figure 2-2. Vertical Speed Indicator Replacement 369E/F Helicopters
Reissued 01 February 1985 2-3/2-4

SECTION III
3-1. GENERAL INFORMATION. Procedures in 3-5. INSTALLATION OF VERTICAL SPEED

this section may be performed at operators dis- INDICATOR AND BOLT LIGHT -MODEL 369E,;-F
cretion and provide complete instructions for ini- HEL~COPTERS.
tial installation of the vertical speed indicator. a. Remove protective plug from rear of
Information in the installation instructions is pre- veE;tical speed indicator (2) and install union (1)
sented as additional procedures to those for main- as shown in fig. 1-1.
tenance of standard instruments in HMI Vol i. b. Insert vertical speed indicator (2) into
(Reference is made in instructions to applicable ins~trument panel and secure with two screws (11)
data in HMI Vol 1 to accomplish installation of as shown in fig. 1-1.
the vertical speed indicator. c. Remove plug and nut from bolt light (10)
and install in mounting hole on vertical speed
3-2. PREPARATION. Preparation for installa- indicator (2). Position bolt light (10) to illuminate
tion of the vertical speed indicator includes the over indicator face as shown in fig. 1-1.
following. d. Retrieve wire L537J20N from console
a. Identify all components, including attaching electrical wire harness 369D24155 and attach it
hardware, or components removed for access to to tab (9).
work areas. Protect components from damage e.Installwashers las required)l tab (9)?
and foreign matter until installed. washer (8). lockwasher (7). nut, and plug to bolt
h. Check all cockpit electrical switches for light (10) as shown in fig. 1-1.
OFF condition. f. Attach contact (12) to white pig-tail wire
DS134 (from plug on bolt light) and connect to
TB503-1L.
NOTE: Make sure BATT-OFF-EXT switch
g. Remove static line from altimeter and
is OFF.
connect tube (4) as shown in fig. 1-1.
h. Remove static line from airspeed indicator
3-3. REMOVAL OF INSTRUMENT PANEL and connect tube (5) as shown in fig. 1-1.
EQUIPMENT. i. Install tee (6) bet-ween tubes (4) and (5) in
a. Remove instrument panel hood and left and position shown in fig. 1-1.
right instrument panel fairings (Section 171 j. Connect one end of tube (3) to union (1) on
HMI Vol 1) 369D and 369HS helicopters only. vertical speed indicator (2) and the other end to
b. Remove blank panel from space directly tee (6) as shown in fig. 1-i.
bel-~w altimeter (A, fig. 1-2 on 369D and 369HS
helicopters or A? fig. 1-1 on 369E/F 3-6. COMPLETION OF INSTALLATION.
helicopters). a. Check entire installation forcompleteness.
b. Check all static pressure lines (tubes).
3-4. INSTALLATION OF VERTICAL SPEED c. Clean all foreign material from instrument
INDICATOR MODEL 369D AND 369HS panel.
HELICOPTERS. d. Reinstall instrument panel left and right
Using mounting hardware 13, 14, bracket
a. fa~ing and hood (Section 17, HMI Vol 7)
assembly (4), and clamp assembly (3), install 369HS and 369D helicopters only.
vertical speed indicator (15) in instrument panel e. Perform operational check of completed
as shown in figure 1-2. vertical speed indicator installation.
b. Remove static line and fitting from airspeed f. Revise weight and balance records (1Jara 3-7).
indicator; replace fitting with connector (8),
tube (7) and tee (6). Connect static line to tee 3-7. WEIGHT AND BALANCE.
as shown in figure 1-2.
c. Remove protective plug from rear of 3-8. GENERAL. Weight and balance changes
veT;tical speed indicator (15) and install O-ring~ resulting from installation of the vertical speed
(12), reducer (11), adapter (10) and union elbow indicator are listed intable 3-1. After installa-
(9) in indicator. tion of vertical speed indicator, incorporate
d. Connect line (5) to tee (6) and union changes in helicopter weight and balance records
elbow (9). as instructed in HMI Vol 2.

Table 3-1. Weight and Balance Data
Longitudinal Longitudinal
Weight Change Arm Moment Change
Version (Ibs) tin) (in-lbs)
Basic t1.7 43. 1 t73
-503 43. 1 t-69

CSP
012
Publication No. CSP012
Illustrcrted Parts List

and
FOR
TRANSPONDER INSTALLATION (KT-76), (KT-76A)

Part No. 369B90073 Basic,
369H90073-501, 503, -505
USED ON HUGHES 500 SERIES (MODEL 369) HELICOPTERS
~3) Hughes Helicopters, Inc.
COD481540 Reissued 1 April 1984

NI FG I
INTRO
REe6~RD OF REVISIONS
CSP-012
MFG REV
CSP-012 Reissue 4/1/84 4/11/96 ATP/GH


CSP-012 Opt Eqpt Manual Table of Contents
TABLE OF CONTENTS
Section Page Section Page
FOREWORD F-l 1 ILLUSTRATED PARTS LIST

(CONTINU EB)
this Manual........... F-l 1-2. Group Assembly Parts
F-2. Applicability F-l List 1-1
F-3. Compatibility of Com- 1-3. Illustrations 1-1
bined Optional
Equipment. F-l a MAINTENANCE INSTRUCTIONS.. 2-1
F-4. Organization of 2-1 2-1. General Information 2-1
Contents FF-1
F-5. Use of this Manual F-l
2-3. Reference Data 2-1
F-6. Related Publications..... F-l
2-4. Removal KT-76/or KT-76A
F-7. Literature Changes 2-1
Transponder
and Revisions F-l KA-48 (Probe)/or
2-5. Removal
KA-60 (Blade) Antenna... 2-1
ILLUSTRATED PARTS LIST..... 1-1 2-6. Inspection 2-1
2-7. Installation 2 -2
and Contents...... 1-1 2-8. Wiring Diagram........ 2-2

1-1. Scope
i/ii
FOREWORD
F-l. PURPOSE AND CONTENT OF THIS coverage of entire systems, major equipment
MANUAL. This manual supplements information groupings, and major components that are similar
contained in HMI Vol 1 and 369 Series IPC, or associated. Procedures for each of these are
and contains instructions for maintenance of the presented in sequence as defined in Section I,
KT-76 and KT-76A transponder installation. HMI Vol i.
This manual also contains parts lists for procur- USE OF THIS MANUAL. This manual is
F-5.
ing replacement parts for the KT-76 and KT-76A for use by operators of the Model 369 Series
transponders. helicopters equipped with a KT-76 and/or a
KT-76A transponder. Although this manual is a
F-2. APPLICABILITY. The KT-76 and KT-76A
separate publication, it should be kept with the
transponder is applicable for use on Hughes 3691),
appropriate HMI Vol 1, HMI Vol 2, 369 Series
E, F model helicopters. IPC and other handbooks listed in Section I,
HMI-Vol 1 that form the primary information
file for the helicopter.
OPTIONAL EQUIPMENT. For compatibility
information on which optional equipment may or F-6. RELATED PUBLICATIONS. Reference is
may not be used in combination at the same time,
refer to Section 21, HMI Vol I. 369 Series IPC as required to accomplish
instructions contained herein.
F-4. ORGANIZATIONOF CONTENTS. The
contents of this manual are grouped into sections F-7. LITERATURE CHANGES AND REVISIONS.
as outlined in the Table of Contents. Each Changes and revisions to contents of this manual
are made as defined in Section i, HMI Vol I.
section is organized to provide comprehensive
F-1/F-2
SECTlOlal I
parts list provides, by means of text (parts lists) parts lists furnish information for procuring
and companion illustrations, a complete parts replacement parts for both the KT-76 and
definition of the 369H90073 transponder (KT-76), KT-76A transponders, and shall not be used for
and the 369D24163 transponder IKT-76A) installa- any other purpose.
tions, manufactured by Hughes Helicopters, Inc.,
Culver City, California.
1-3. ILLUSTRATIONS. Illustrations are
NOTE: The illustrated parts lists is organized provided for each group assembly parts list.
and presented in the same manner as the 369D Each illustration is exploded to the extent
Series Illustrated Parts List (369D TPC). necessary to show parts relationship for the
(For information on use, refer to the complete KT-76 and KT-76A transponder
appropriate 369D series IPC. installations.
1-1
NEW ART
369B90073 Installation Dwg of D H versions
1-2
FIG. I I I UNITS USABLE

NO. NO. ASSY CODE
1-1- 369890073-509 PROVISIONS INSTALLATION (without transponder,

located below dash). 1
369890073-507 PROVISIONS INSTALLATION (without transponder,
located in dash) 1
3691190073-505 KING KT-76A TRANSPONDER INSTALLATION
(located below dash) 1
3691190073-503 KING KT-76A TRANSPONDER INSTALLATION
(located in dash). 1
3691190073-501 KING KT-76 TRANSPONDER INSTALLATION
(located below dash) 1
369H90073-BSC KING KT-76 TRANSPONDER INSTALLATION
(located in dash). 1
050-1244-01 KIT, KT-76 INSTALLATION; COMPONENT OF
3691190073 -BSC, 501 1
050-1247-00 KIT, KT-76 INSTALLATION VOLTAGE CHANGE-
OVER; COMPONENT OF 369B90073, -BSC, 501 1
066-1034-01 TRANSPONDER, KT-76 AIR TRAFFIC CONTROL,
COMPONENT OF369H90073, -BSC, 501 1
050-1577-00 KIT KT-76A INSTALLATION; COMPONENT OF
369H90073, -503, -505, -507, -509........... 1
050-1578-00 KIT, KT-76A, VOLTAGE CHANGEOVER; COMPO-
NENT OF 369H90073-503, -505, -507, -509..... 1
066-1062-00 TRANSPONDER, KT-76A, AIR TRAFFIC CON-
TROL; COMPONENT OF 399B90073-503, -505 1
-1 I 2TC13-3 I CIRCUIT BREAKER 1

2TC12-3 I CIRCUIT BREAKER (INTERCHANGEABLE
WITH 2TC13-3. 1
-2 MS21042L3 i NUT. 6
-3 NAS620-10L I WASHER. 16
-4 NAS1096-3-9 I SCREW. 6
-5 MS25281-R3 I CLAMP. 6
-6 KA48 I ANTENNA 1
KA-60 I ANTENNA, USE AS ALT (Provided in
KT-76A Kit) I 1
-7 1 369B90073-11 1 CABLE ASSY. 1

3 6 9H 9007 3 -13 1 CABLE ASSY, COMPONENT OF 369H90073-
BSC, -501.......................... 1
369890073-15 CABLE ASSY, COMPONENT OF 389H90373-

503, -505, -507, -509. 1
-8 1 A4972-6-62 1 NUT, COMPONENT OF 3691190073 -501, -505,
-509.............. 2
-9 NAS620-6L I WASHER............; 2
-10 NASGO1-6 I SCREW. 2

-11 MS21042L06 I NUT, COMPONENT OF 3691190073 -BSC, -503,
-507...... 4
-12 NAS6208L I WASHER. 3
-13 369B90073-5 FILLER, COMPONENT OF 369B90373 -501,
-505, -509............. 2
-14 NASS14P832 -7 j SCREW, COMPONENT OF 3S9H9O0a3 -531,
2
-505, -509
-15 MS17821-4-9 I STRAP, COMPONENT OF 3Ij9H90073-BSC, -501 A/R
-16 MS25036-102 I TERMINAL 1
-17 M525036-149 1 TERMINAL.... 1

-18 MPCMB OiM -H1 I HYTIP TERMINA L 1
1
-19 KC-59-aS I PLUG, COAX
1-3
Section 1 Opt Eqpt Manual CSP-O1S
FIG. UNITS USABLE

NO. NO. ASSY CODE
1-2- 369D24163 -BSC KT-76A TRANSPONDER INSTALLATION....... 1

050-1578-00 1 VOLTAGE CHANGE KIT 14 TO 28 VDC 1
050-1577-00 1 INSTALLATION KIT 1
066-1062 -00 1 TRANSPONDER KT-76A 14 VDC........... 1
-1 2TC13-3 I CIRCUIT BREAKER 1
-2 MS21042L3 I NUT. 6
-3 NAS620-10L I WASHER. 12
-4 NAS-1096-3-9 I SCREW. 6
-5 MS25281-3 CLAMP 6
-6 KA-60 ANTENNA. 1
-7 369D24163-11 1 CABLE ASSY. 1
-8 NAS1096-2-26 I SCREW. 2
-9 MS20470-AD3 I RIVET 6
-10 MS17821-4-9 I STRAP A/R
-11 MS25036-102 I.. TERMINAL 1
-12 MS2 5036-149 1 TERMINAL 1
-13 MP CMB0M -H1 I HYTIP TERMINA L 1
-14 RC-59-78 PLUG, COAX 1
1-4
FIG. UNITS USABLE

NO. NO. ASSY CODE
-20 NAS603 -7 1 SCREW~ 2

-21 NAS620-10L WASHER. 14
-22 3691192072 1 BRACKET, COMPONENT OF 369H90073-BSC,
-503, -507 1
-23 M521042 -L3 I NUT. 6
-24 3691190073 -3 1 BRACKET, COMPONENT OF 369B90073-501,
-505, -509 1
-25 A N960PD10L I WASHER, COMPONENT OF 369D24217
BRACKET ASSY AND 369H90073-BSC, -503,
-507 2
1-5
NEW ART
369D24163 Installation Drawings of E and F versions.
1-6
SECTION II
2-1. GENERAL INFORMATION. The KT-76/or a bracket attached to helicopter floor).

location has
KT-76A transponder installation consists of a Transponder internal panel light dimming is con-
KT-76/or KT-76A transponder, KA-48/or KA-60 trolled by dimming circuits (Section 17,
external
transponder antenna, transponder antenna cables, HMI i). A heat shield on the aft side of the
Vol
transponder unit mounting bracket, interconnect- transponder (KT-76) and/or (KT-76A) houses a
ing wiring, a circuit breaker and miscellaneous 10-ohm 55-watt resistor that drops +28 vdc supply
mounting hardware. The transponder system voltage to +14 vdc for transponder operation. The
provides automatic radar identification of the transponder voltage supply transistor for the KT-
helicopter to any interrogating ground station. 76A (3693) is mounted on the rear of the instru-
The system furnishes helicopter identification in ment console. Transponder weight is approxi-
Mode A, Special Pulse Identification (SPI) pulse mately 3. 0 pounds, including mounting rack.
information to all suitably equipped interrogating
stations within operational range of the system. 2-3. REFERENCE DATA. Table 2-2, HMI
The equipment also contains provisions for alti- Vol i, Sections 17, 20, HMI Vol 1 and
tude reply codes in operation Mode C, to furnish HMI Vol 2.
an interrogating station with helicopter altitude
information, when additional altitude digitizer 2-4. REMOVAL KT-76/or KT-76A

equipment (not furnished) is installed. The trans- TRANSPONDER.
ponder receives ~28 vdc from the main electrical a. 3/32-inch Alien wrench through
Insert a
system when the XPDR (transponder) circuit face transponder. Rotate wrench counter-
plate of
breaker on the instrument panel is ON. Proce- clockwise releasing holddown device; pull trans-
dures in Section 2 provide maintenance informa- ponder from mounting tray.
tion for the transponder system relating to system b. Disconnect antenna coaxial cable at rear
installation in the helicopter. For maintenance of mounting tray.

information on transponder system components c. Disconnect wiring from TB502 either 1B,
beyond the scope of coverage in the following 3E, 9A, CB126 and TB6. Remove straps secur-
paragraphs (such as transponder repairs, trouble- ing wire harness to ships wiring.
shooting, internal schematics, etc. refer to d. Remove hardware securing mounting tray
manufacturers publications (table 2-2, HMI- to bracket at rear of tray and hardware at front
Vol i). of mounting tray; remove mounting tray from
instrument panel. Do not remove bracket unless
2-2. DESCRIPTION. The KT-76/or KT-76A replacement is necessary.
transponder receives radio frequency (rf) inter-
rogating signals from the KA-48/or KA-60 trans- 2-5. REMOVAL KA-48 (PROBE)/OR KA-60
ponder antenna and automatically transmits coded (BLADE) ANTENNA.
reply rf signals in answer through the same a. Disconnect coaxial cable from antenna.
antenna. The transponder contains a receiver- b. Remove nut/nuts from antenna; pull antenna
transmitter that receives at 1030 MHz and trans- from helicopter structure, retaining washers for
mits at 1090 MHz. The transponder requires reassembly.
approximately 1.3amperes of current (maximum) c. If antenna coaxial cable is to be removed,
at ~28 vdc. Transmitter power is 200 watts (p~ak) remove clamp assemblies attaching antenna
minimum and antenna impedance is 50 ohms. The cable to other coaxial cable and remove cable
transponder is a completely solid state device, from helicopter.
except for the transmitter oscillator. The trans-
ponder is located at the lower center of the heli- 2-6. Inspecttransponder and
INSPECTION.
copter instrument panel (alternate transponder mounting tray dents, breaks, corrosion and
for
location for the KT-76A is directly below the other obvious damage. Inspect coasial cables for
switch and circuit breaker panel). A transponder kinks, breaks, and damaged insulation. Inspect
mounting tray and bracket secures the transpon- wire harness for broken wires, frayed insulation
der inside the instrument panel console (alternate and damaged terminals.
2-1
2-7. INSTALLATION. Installantenna, mounting diagram for installation, troubleshooting and

tray, transponder using reverse order of
and maintenance of KT-76 and KT-76A transponder
removal procedures. installation. For internal schematics of trans-
ponder, refer to manufacturers publications
2-8. WIRING DIAGRAM. Figure 2-1 is a wiring (table 2-2, HMI Vol 1).
PART OF J760
r--------------
GND 12
TB502-0
LIGHT DIMMER 11 Kiznzo XPDR
CB126
W3-2
10a
t14 VDC KT1AZOKT1B20
55 WATT 3A
JUMPER
KA-48
P762 J762
ANTENNA
KT-76
TRANSPONDER
L----_-__
Figure 2-1. KT-76 Transponder Interconnection Wiring Diagram
2-2
CSP
0~5

and
FOR
AUTOMATIC DIRECTION FINDER (KR 85)

Part No. 369B90067 Basic,
369B90067-501, 369B90067-51
and 369B90067-61
Hughes Helicopters Mn--w--/--,,m,
COD671080 Issued 1 September 1976

NI FG I
INTRO
RECORD OF REVISIONS
CSP-015
MFG REV
RECORD OF TEMPORARV REVISIONS
P~b
ATP REV DATE REV REMOVE
C8F015 Opt H;u~uPil Table of Contents
AUTOMATIC DIRECTION FINDER
iABLE OF CONTENTS
Section Page
FOREWORD F-l
F-l. Purpose and Content

of this Manual F-1
F-9, Compatibility of
Combined Optional
Equipment F-l
F-l. Organization of Contents
F- 5, Use of this Manual .F-l
F-?. Literature Changes
and Revisions F-l
1-1. Scope and Contents 1-1

1-2. Group Assembly
Parts List 1-1
2 MAUNTENANCE INSTRUCTIONS.. 2-1
2-1, General Information,.,,. 2-1

2-2. Description of
KR 85 ADF Receiver 2-1
2-3. Description of
M 225 ADF Indicator 2-1
CgPO11 Opt Eqpt HnrPupl Table of Contents
AUTOMATIC DIRECTION FINDER
TABLE OF OONTFNTS
Section Page
2 MSTRUCTIONS
(CONTINUED)
2-1. Description of KA 12
ADF Lnop Antenna 2-1
Loop Antenna Cable 2-1
2- 6. Description of
369H80067-3r Wire
Harness Assembly,,,,,, 2-1
2-7. Description of
ADF Sense Antenna 2-3
2-8. Description of
Etolse Filters 23
2- 10. Troubleshooting 2-3
Operational Check,..... 2-3
2-12. Alignment 2-3
2-13. Lnspectlon 2-3
2-11. Replacement of
1(1 225 Indicator........ 2-3
KR 85 ADF Receiver 2-5
Loop Antenna Cable 2-5
2-17. Replacement of KA (12
ADF Loop Antenna...... 2-5
2-18. Adjustment 2-5
2-19. Repair 25
2-20. Wiring Diagram 2-5
FOREWORD
MANUAL. This manual supplements information groupings, and major components that are
contained in HMI Vol 1 and 369D IPC, and similar or associated. Procedures for each of
contains instructions for maintenance of the these presented in sequence
are as defined in
KR 85 automatic direction finder (ADF) installa- Section 1,HMI Vol 1.
tion. This manual also contains parts lists for
procuring replacement parts for the automatic F-5. USE OF THIS MANUAL. This manual is
direction finder installation. for usebyoperators of the Model 369D helicopter
equipped with KR 85 automatic direction finder.
F-2. APPLICABILITY. The KR 85 automatic Although this manual is a separate publication, it:
direction finder is
applicable for use on any should be kept with HMI- Vol 1, HMI- Vol 2,
Hughes 500D (Model 369D) helicopter. 369D IPC and other handbooks listed in Section 1,
HMI- Vol 1 that form the primary information file
F-3. COMPATIBILITY OF COMBINED for the helicopter.
information on which optional equipment may or F-6. RELATED PUBLICATIONS. Referenceis

may not be used in combination at the same time, made to applicable portions of HMI- Vol 1 and
refer to Section 21, HMI Vol 1. 369D IPC as required to accomplish instructions
contained herein.
F-4. ORGANIZATION OF CONTENTS. The
as outlined in the Table of Contents. Each sec- Changes and revisions to contents of this manual
tion is organized to provide comprehensive are made as defined in Section 1, HMI Vol 1.
F-1/F-2
SECTION I
1-1. SCOPE AND CONTENTS. This illustrated 1-2. GROUPASSEMBLY~PARTS LIST. The
and companion illustrations, a complete parts replacement parts for the automatic direction
definition of the 3691190067 Automatic Direction finder installation and shall not be used for any
Finder (I(R 85) installation, manufactured by other purpose.
Hughes Helicopters, Culver City, California.
1-3. ILLUSTRATIONS. Anisometric illustration
MOTE: The illustrated parts list is organized is provided forthe group assembly parts list. The
and presented in the same manner as the 369D illustration is exploded to the extent necessary to
Series Illustrated Parts List (369D IPC). (For show parts relationship for the complete automatic
information on use, refer to the 369D IPC.) direction finder installation.
1-1
f~,
9
4
ALTERNATELOCATION 8
10 9
J 11
/20 ii
17/ f
i i li.i o 2
O
9
ii
i i i
12~8
12
I
I
26
Is
.p 33
1!
1
~LO/ I if.
I
31 32 47-089
Figure I-1. Automatic direction finder installations
1-2
CSP-015 Opt %qpt Manual Section 1
FIG. UNITS
INDEX PART DESCRIPTION PER
NO. NO. I I ASSY
1-1- 369B90067 AUTOMATIC DIRECTION FINDER (I(R 85) 1

(See figure 1-2 for further bkdn)
369H90067-501 AUTOMATIC DIRECTION FINDER(KR 85) 1
(Provisions instl)
-1 2TC13-2 CIRCUIT BREAKER 1
-2 MS51957-43B I SCREW. 9
-3 MS27129-9 WASHER 1 9
-4 MS35214-29 SCREW I 1
-5 MS35214-31 SCREW 1 2
-6 MS35214-32 SCREW I 1
-7 MS35214-109 SCREW I 1
-8 AN9s0XC6L I WASHER 1 5
-9 369Bs423- 505 HOOD I 1
KR 85 DIGITAL AUTOMATIC DIRECTION FINDER I 1
(ADF) EQUIPMENT
-10 369B90067-31 WIRE HARNESS ASSY 1
-11 024-0003-00 COAXIAL CABLE (Supplied with KR 85) I 1
-12 32863 1 LUG 1
-13 MS25036-102 LUG 3
-14 MPCMB2M-HI I HYTIP 3
-15 D121 I SLEEVE I 1
-Is 050-1165-05 I CONNECTOR (SET) (Supplied with KR 85) I 1
with wire harness assy 3691190067-31)
(Used
_17 155-2008-01 LOOP ANTENNA CABLE (Supplied with KR 85) 1
-18 MS35214-28 SCREW 3
-19 NAS620A6L WASHER 3
-20 066-3017-00 KI225 INDICATOR (Supplied with KR 85) 1
-21 MS21042-08 NUT 2
-22 M851957-433 SCREW 2
-23 AN9s0A8L I WASHER 2

-24 369B90067-9 1 CLAMP I 1
-25 369B900s7-33 FILLER I 1
-26 NAS623-2-1 I SCREW 1 4
-27 066-1023-00 AUTOMATIC DIRECTION FINDER RECEIVER (ICR 85) 1
(Supplied with KR 85)
-28 MS21042-08 I NUT 2
-29 MS35214-40 SCREW 2
-30 NAS 62 0A8L WASHER 2
-31 MS2042 6AD3 RIVET 1 8
-32 1 MS21075-08 NUTPLATE 4
-33 369B90067-21 1 PANEL FACE ASSY I 1
1-3
1C
I
2 5I
Jr$
B
7 \-PO
g
15
i, Is
s
i
lo 11
o O 12 W
47-090
Figure 1-2. Automatic direction finder antenna and filter

installations
1-4
FIG. L~N ITS

NO. NO. ASSY
1-2- 3691190067 AUTOMATIC DIRECTION FINDER (KR 85) (Cont) REF

1-1 for initial bkdn)
(See figure
369H90067-501 AUTOMATIC DIRECTION FINDER (KR 85).......,... 1
(Provisions instl)
-1 MS35082-1 NUT 3
-2 MS35338-41 WASHER 3
-3 AN960- 6L WASHER 6
-4 MS21042-3 NUT 2
-5 AN9 60PD 1 OL I WASHER 2
-6 3691190067-39 SPACER 2
-7 369116461 1 FILTER I 1
-8 369B6615-155 1 DECAL 1
NAS671-6 NUT 2
-9
AN935- 6L I WASHER 2
-10
-11 AN960C 6L WASHER 1 4
MS25036- 102 TERMINAL 2
-12
NUT 2
-13 MS21042-08
,14 AN960C8L I WASHER 4
MS51957143 SCREW 2
-15
FILTER 1
-16 1549
NAS1351C4-20 SCREW 2
_17
-18 155-2008-01 LOOP ANTENNA CABLE (Supplied with KR 85) REF
(See figure 1-1 for NHA)

-19 071-1006-11 1 KA 42 ADF LOOP ANTEN~A (Supplied with KR 85) 1
AN960C10 I WASHER 2
-20
369B90146-503 ANTENNA INSTL (Use 3691190146-5()5 if 1
-21
navigation radio option is installed)
1-5
i
ij
m2,
a,
12 t
ib,, ,Ir,bj
I
i I I
12
%II11~45 6 14
i I
7
8
3 9
16
23
25
26
ir 10
15
21
1730
29
\I\
j
22- _~
)t
37~
ii
36
39 811~
40
12
j~t
47-088
Figure 1-3. Automatic direction finder alternate indicator and receiver installation
provisions
1-6
FIG. UNITS
NO. NO. ASSY
1-3- 369B90067 AUTOMATIC DIRECTION FINDER (I(R 85) (Cont) REF

(See figures 1-1 and 1-2 for initial bkdn)
369B90067-51 AUTOMATIC DIRECTION FINDER (KR 85) I 1
(Provisions for alternate locations of indicator)
-1 2TC13-2 CIRCUIT BREAKER (See figure 1-1 for NHA).,..,, REF
-2 MS51957-43B SCREW (See figure 1-1 for NHA) REF
-3 MS27129-9 WASHER (See figure 1-1 for NHA) REF
-4 MS35214-29 SCREW (See figure 1-1 for NHA) REF
-5 MS35214-31 SCREW(See figure 1-1 for NHA) REF

-6 MS95214-32 1 SCREW (See figure 1-1 for NHA) REF
-7 MS35214-109 I SCREW(See figure 1-1 for NHA) REF

-8 AN960XC 6L WASHER (See figure 1-1 for NHA) REF
-9 3 69H 642 ;3- 505 HOOD (See figure 1-1 for NHA) REF
_10 N1835214-28 SCREW (See figure 1-1 for NHA) REF

-12 066-3017-00 KI225 INDICATOR (Supplied with KR 85) REF
-13 MS21042-06 NUT 4
_14 NAS620A6L I WASHER 4
-15 MS24693C26 I SCREW 4
-16 369B90067-41 1 PLATE........, 1
369H90067-61 AUTOMATIC DIRECTION FINDER (KR 85)(Provisions for REF
alternate location of receiver)(See figure 1-1 for NHA)
-17 MS21042-3 I NUT I 1
-18 MS25281-7 I CLAMP 1
-19 MS51958-63 SCREW 1
-20 AN9 60PD10L I WASHER 1
-21 MS21042-3 NUT 2
-22 AN9 60PD10L I WASHER 2
-23 MS51958-65 1 SCREW 2
-24 HL-55-08Z I RESISTOR 1
-25 MS2042 6AD3 RIVET 4
-26 MS21071-06 I NUTPLATE 2
-27 369B90067-55 1 SUPPORT, 1
-28 369B901)67-65 WIRE HARNESS ASSY (Make from wire harness assy I 1
369H90067-31)(See figure 1-1 for details of-31 assy)
-29 MS25181-1 SPLICE I 1
-30 MS25030- 102 LUC 1
-31 NAS1096-3- 12 SCREW 1

-32 AN960PD10L WASHER 1
-33 NAS 623- 2 1 SCREW 1-1 for NHA)
(See figure 2
-34 066- 1023-00 AUTOMATIC DIRECTION FINDER RECEIVER (KR 85) REF
(Supplied with KR 85) (See figure 1-1 for NHA)
-35 MS51958-61 I SCREW 2
-36 AN620A10L WASHER 2
-37 3691990067-45 1 CLAMP ASSY, OUTED, 1

-38 369B90067-47 1 CLAMPASSY,INBD I 1
-39 369H90067-57 FILLER 1
-40 MS24693C26 I SCREW 6
-41 369B90067-43 1 PANEL 1
-42 C-8104-832 1 NUTPLATE 2
1-7/1-8
CSP-O1B Opt Eqpt Manual Section 2
SECTION II
2-1. GENERAL INFORMATION. The KR 85 2-3. DESCRIPTION OF 10225 ADF INDICATOR.

installation is The
used for homing on selected radio stations to visual indication of the bearing of incoming radio
obtain accurate bearing
information. The instal- signals. The heading card may be rotated by use
lation consists of a KR 85 ADF receiver and of the HDG control at the front of the indicator.
KI 225 indicator mounted in the instrument panel. The heading pointer rotates to indicate the bearing
A KA 42 loop antenna is attached to the underside of the radio signal source in degrees. The indica-
of the fuselage. A sense antenna lead-in wire is tor is flush mounted instrument
on the helicopter
attached to the ADF/UHF nav antenna on the panel. For detailed theory of operation, refer to
underside of the fuselage. The installation the manufacturers publication (table 2-2,
receives +28 vdc electrical power from the main HMI- Vol 1).
power bus through the a-ampere ADF circuit
breaker on the instrument panel. Figure 2-1 2-4. DESCRIPTION OF KA 42 ADF LOOP
provides a wiring diagram for the ADF installa- 19,
tion. System components are described in the fig. 1-2) windings wound at right
consists of two
following paragraphs. angles. The windings are symmetrical with
respect to ground to prevent unwanted pickup.
NOTE: An integrated interphone communica- The magnet field of the radio signal induces a
tion system (ICS) must be installed in the voltage in the loop antenna. The relative direction
helicopter for use with the ADF installation. of the signal source determines the amplitude of
The ICS audio equipment (headset, switch and the voltage induced in each antenna winding.
jack assembly and control unit) are required These voltages are used in the ADF indicator to
for reception of ADF voice and code signals. position theheading pointer to indicate the angle
The electrical interface of the ADF and ICS at which the radio signal is entering the loop
is shown in figure 2-1, and the ICS electrical antenna. The loop antenna is mounted on the
circuitry is described in the ICS Opt Eqpt underside of the fuselage below the pilots com-
Manual (table 21-1, HMI- Vol 1). partment. The ADF loop antenna is connected to
the ADF indicator via the 155-2008-01 loop
2-2. DESCRIPTION OF KR 85 ADF RECEIVER. antenna cable.
The
for homing and direction-finding on the source of 2-5. DESCRIPTION OF KA 42 LOOP ANTENNA
low-frequency, amplitude- modulated or
interrupted-carrier radio signals within the range is a four-conductor shielded cable. The
of 200 kHz to 1699 kHz. The digitally selected loop- antenna end of the cable is terminated into a
frequency channels may be selected in 1 kHz terminal box, which contains four 0. 2 uH chokes
increments. The receiver is flush mounted in the that aid in phasing the antenna voltages.
helicopter instrument panel. Panel controls
enable the operator to select frequency and three 2-6. DESCRIPTION OF 369H90067-31 WIRE
modes of operation, and to adjust audio volume. Se17n-
The audio output of the receiver is available at bly (10, fig. 1-1) consists of shielded cable,
the headsets of the interphone communication wiring, connectors, and connecting hardware.
system (ICS). The receiver also supplies signals It is used to interconnect the ADF receiver, ADF
to the KI225 indicator for visual indication of indicator, sense antenna, and helicopter integrated
radio signal bearing. Reception range of
source interphone communication system (ICS). The
the receiver is dependent on helicopter altitude wire harness assembly also includes a 1Cohm,
and weather conditions. For detailed theory of 55-watt, fixed wire-wound resistor (R85) which is
operation of the ADF receiver, refer to the manu- used to drop the 28 vdc from the ICS to 14 vdc
facturers publication (table~ 2-2, HMI Vol 1). required by the ADF system. A 48- inch coaxial
2-1
ADF SENSE ANTENNA ADF LOOP ANTENNA

(MODIFIED ASP-3-BL CABLE (MODIFIED KING 155-2008-01) (NOTE 9)
ANTENNA) (NOTE 4) P854 P852
3 1 Js52 1
i ADF RECEIVER 1
IANTENNA
LOOP
(KA 42)
(KING 071-1006-1
8
1
6
2
3
4
j LOOP ANTENNA
RF IN
(KING KR 85)
Issllpasl (NOTE 3) 5
(NOTES 3. 5)
SENSE ANTENNA RF IN 16
(NOTE 611
L_ ENCLOSURE
(NOTE 10)
P853 5851
ADF SENSE ANTENNA CABLE (NOTES 3. 6)
L (NOTE 6)
SHIELD (GROUND)IB
SHIELD (GROUND) 2 U SHIELDIGROUND)
RF CABLE INOTES 3, 8)
ADFRFIN 1 XIADF RF OUT
14V OUT TO 900 SW ITCH 1 8 Kf185-1A22 N 14V IN TO 90" SWITCH
9V OUT TO SERVO MOTOR 1 10 KR85-2A22 I H I 9V IN TO SERVO MOTOR
14V ODT TO SERVO MOTORI 11~- KR85-3A22 L 14V IN TO SERVO MOTOR
OSC OUT 1M SERVO OSC OUTPUT IN
OVRESROTOM
TO SERVO
KR85-4A22
KR85-5A22 K TO SERVOMOTOR
SERVO AMP OUTPUT 14 KR85-6A22 J SERVOAMPOUTPUT IN
R85
TO SERVO MOTOR
14n
+TB501-1 TO SERVO MOTOR
+28 VDC
+14 VDC POWER IN 4 KR85-7B22 KR85-7A22
55W
(NOTE 6)
-P p, +TB502-10B
AdF AUOIO HI OUT 1 C ADF AUDIO
5 KR85-8A22-RED B
HI OUT (NOTE 7)
ADF AUDIO LO OUT 6

Ij KR85-8A22-BLU
TB502-3D
D
ADF AUDIO
LO OUT (NOTE 7)
PANEL LAMPS POWER IN 7 t- KR85-9B22 F

"TB502-8D FROM
PANELLIGHT +LIGHTS
j_
KR85-9A22 D
IN DIMMINC
L5j3A22
CIRCUIT
GROUND 9 KR85-10B22 P GROUND
KR85-llA22 ~TB6-2 ADF INDICATOR
KR85-10A22N GROUND (KING KI 225)
CAB~&I BUS I (NOTES 3.5)
TO+TB101 1
~----RV522A16
P506AN16-----o
+28VDC BUS 2A
NOTES:
1. THI S WIRING DIAGRAM SHOULD BE USED WITH THE WIR ING DIAGRAM FOR THE HELICOPTER ELECTR ICAL
SYSTEM (HMI-VOL 1) AND THE WIR ING DIAGRAM FOR THE INTEGRATED INTERPHONE COMMUN ICATION
SYSTEM (ICS)FOR COMPLETE WIRING INTERCONNECTION INFORMATION.
2. ASTER ISK I+) INDICATES PART OF HELICOPTER BASIC ELECTR ICAL SYSTEM.
3. PART OF KING KR 85 ADF SYSTEM.
4. ASP-3-BL ANTENNA MANUFACTURED 8Y ANTENNA SPECIALISTS PRODUCTS.
5. REFER TO MANUFACTURERS PUBLICATION (TABLE 2-2, HM I-VOL 1) FOR INTERNAL MAINTENANCE OF
MAJOR COMPONENTS.
6. PART OF KR 85 ADF WIRE HARNESS ASSEMBLY THAT ALSO INCLUDES WIRING ATTACHED TO AND BETWEEN
CONNECTORS.
7. FOR WIRING INTERCONNECTIONS. REFER TO INFORMATION ON THE INTEGRATED INTERPHONE
COMMUN ICAT ION SYSTEM (ICS).
8. DO NOT ALTER LENGTH.
9. AT REPLACEMENT. REPLACEMENT CABLE MUST BE WIRED ON END AT P854 AS SHOWN AND MODIFIED
ACCORDING TO MANUFACTURERS INSTRUCTIONS FOR CORRECT PHASING WITH UNDERSI DE MOUNTED
LOOP AND ADF SENSE ANTENNA.
10. ALL INDUCTORS ARE SAME VALUE (0. 2 MICROHENRIES).
47-092
Figure 2-1. Automatic direction finder interconnection wiring diagram
2-2
cable connected between the two harness connec- for aid in troubleshooting. If troubleshooting
tors feedsloop antenna r-f signals from the ADF indicates that the trouble is in the ADF indicator
indicator to the ADF receiver, or the ADF receiver, refer to the manufacturers
publication (table 2-2, HMI- Vol 1) for unit

2-7. DESCRIPTION OF ADF SENSE ANTENNA. troubleshooting and corrective action.
The
incoming radio signals which are used to produce NOTE: ADF audio is reproduced by compo-
an audio output. Also, the sense antenna input is nents of the integrated interphone communi-
added to the loop antenna input to obtain pointing cation system (ICS) which, in itself, may be
modulation. The ADF sense antenna is a modified the source of ADF audio trouble. When ADF
Antenna Specialists Products ASP-3-BL whip an- audio malfunction is encountered, refer to
tenna. It is mounted fore-and-aft on the ADF the ICS Opt Eqpt Manual (table 2-21, HMI
sense/vhf nav antenna bracket at the center under- Vol 1) for troubleshooting procedures for
side of the fuselage structure. A nut and washer that portion of ADF audio circuitry.
secure the antenna base to an aluminum plate and
phenolic insulator on the forward side of the 2-11. OPERATIONAL CHECK. The-following
antenna bracket with the antenna rod element procedure is used to verify the capability of the
extending aft through a grommet in the aft side of ADF system to function properly. The procedure
the antenna bracket. The grommet, phenolic should be performed anytime a malfunction is
insulator and three nylonflanged washers elec- suspected, and prior to normal use after repair.
trically isolate the antenna element from the _a. Position the helicopter on a compass rose.
metal antenna bracket. The sense antenna has an Using a strong station in the 200 kHz to 415 kHz
over-all length of 60 inches, including the antenna band, obtain ADF bearings for increments of
base. The ADF sense antenna cable, a part of the 15 degrees beginning with the helicopter on a
ADF 3691190067-31/51 wire harness assembly, 0 degree heading. Make quadrantal error correc-
connects to the antenna base at the forward side tions, if necessary. The combined error should
of the antenna bracket. Clips, clamps and other not exceed ~5 percent.
miscellaneous hardware furnish attachment for b. Verify that the ADF audio is present and
the ADF sense antenna cable at various routing that sufficient volume adjustment is available.
locations. A thermoplastic fairing is secured to
the underside with sponge rubber seal
fuselage 2-12. ALIGNMENT. Refertothe manufacturers
with adhesive backing and screws and washers, HMI- Vol 1) for instruc-
over the antenna bracket. When the helicopter is tion for aligning the ADF system.
also equipped with a vhf navigation antenna instal-
lation, a vhf navigation antenna is secured to the 2-13. INSPECTION. Inspect components of the
underside of the- antenna bracket. ADF system in accordance with FAA AC 43. 13-1A
and standard avionics maintenance practices, and
2-8. DESCRIPTION OF NOISE FILTERS. The the following:
two 16, a. Inspect all components for obvious physical
fig. 1-3) are sealed and potted L-C devices used damage, corrosion and evidence Of electrical
to filter out inductive noise which could affect overheating.
operation of the ADF. FL100 is installed in _b. Inspect the ADF indicator and ADF receiver
series in the de power input line to the gyro for loose or missing controlknobs, damaged or
system. FL101 is installed in series in the de obscured markings, and loose or damaged
power input line to the strobe light, connector s.
c. ;Inspect assembly and loop
the wire harness
2-9. REFERENCE DATA. Informationonheli- damage, loose
antenna cable for cuts and other
copter components that interface with the ADF connectorsor connecting hardware, and frayed
system is in HMI- Vol 1 and 369D IPC. For insulation.
information associated optional avionics equip-
on d. Inspect the noise filters for case damage
ment used with the ICS system, refer to the and loose terminals.
applicable Opt Eqpt Manual for that specific
equipment (Section 21, HMI- Vol 1). 2-14. REPLACEMENT OF KI225 INDICATOR.
2-10. TROUBLESHOOTING. If the ADF system CAUTION: Check that all electrical power
does not operate properly during operational is OFF.
check or normaluse, refer to table 2-1 for aid
in locating the probable trouble and for corrective _a. Remove instrument panel side fairings
action. Refer to the ADFwiring diagram (fig. 2-1) (Section 17, HMI- Vol i).
2-3
Table 2-1. Troubleshooting
No audio in either ADF circuit breaker Set circuit breaker

ADF or BFO mode (1, fig. 1-1) not ON. to ON.
and indicator
inoperative. No d-c power on Refer to Section 19,
helicopter main bus. HMI Vol 1.
Disconnected or Connect or repair

defective wire harness wire harness
assembly. assembly.
ADF circuit breaker Overload or short Repair or replace

trips. circuit in ADF ADF receiver.
receiver
Overload or short Repair or replace

circuit in ADF indicator. ADF indicator.
Resistor R-85 (24, fig. Replace resistor.

1-3) defective.
Erroneous bearing ADF system out of Align ADF system

indication, audio alignment. (para 2-12).
OK.
Defective ADF Repair or replace
indicator. ADF indicator.
Defective or damaged Repair.or replace

ADF loop antenna. ADF loop antenna.
Disconnected or de- Connect or repair

fective loop antenna loop antenna cable.
cable.
No ADF audio, ADF system out of Align ADF system

bearing indication alignment. (para 2-12).
OK.
Defective ADF Repair or replace
receiver. ADF receiver.
Defective ADF sense Repair or replace

antenna lead-in wire. sense antenna ADF
lead-in wire.
No ADF audio, Defective ADF Repair or replace

bearing indication receiver. ADF receiver.
incorrect,
power OK.
ADF audio weak, ADF receiver audio Adjust ADF receiver

not adjustable potentiometer audio potentiometer
to satisfactory incorrectly (para 2-18).
level with adjusted.
AUDIO control.
2-4
b. Remove attaching parts (2 thru 8, fig. 1-1) 2-17. REPLACEMENT OF KA 42 ADF LOOP
an~ remove hood (9).
c. Disconnect two connectors at rear of a. Gain access to the pilots underfloor com-
indicator (20). partment (Section 2, HMI- Vol 1).
d. Remove attaching parts and remove b. Remove loop antenna terminal box attaching
ind~icator. parts and disconnect loop antenna cable. Retain
e. Install the replacement indicator in reverse spacer washers and rubber gasket for reconnec-
order of removal. tion of cable terminal box.
c. Remove loop antenna attaching parts and
2-15. REPLACEMENT OF KR 85 ADF RECEIVER. remove loop antenna.
a. Check that all electrical power is OFF. d. Install replacement loop antenna in reverse
i;. Remove instrument panel side fairings order of removal. Check that the arrow on the
(Section 17, HMI- Vol 1). antenna is pointing to the forward end of the
c. Remove attaching parts (2 thru 8, fig. 1-1) helicopter, and that the antenna cable wiring is
and remove hood (9). connected for proper phasing. Refer to the manu-
d. Disconnect connector at rear of receiver facturers publication (table 2-2, HMI- Vol 1).
(27.
e. Remove attaching parts (21, 22, 23) and 2-18. ADJUSTMENT. If the volume of the ADF
remove clamp (24) and filler (25). audio can not be to a satisfactory level
adjusted
f. Remove screws (26), then carefully with- by of the volume control on the ADF receiver,
use
draw receiver through front of instrument panel. and the trouble is not in the integrated interphone
communication system (ICS), adjust the volume
ff. Install the replacement receiver in reverse
order of removal, potentiometer ih the ADF receiver in accordance
with the instructions in the manufacturers
2-16. REPLACEMENT OF LOOP ANTENNA publication (table 2-2, HMI- Vol 1).
CABLE.
a. Check that all electrical power is OFF. 2-19. REPAIR. Refer to Section 19 of HMI- Vol 1
b. Remove instrument panel side fairings for electrical repair instructions. Replace dam-
(Section 17, HMI- Vol 1). aged cable clips and other attaching hardware with
c. Disconnect loop antenna cable connector new parts. When a malfunction occurs in the ADF
atrear of indicator (20, fig. I-i). indicator or ADF receiver, replace parts found to
d. Gain access to pilots underfloor compart- be defective by the troubleshooting procedures
m~t (Section 2, HMI- Vol 1). provided in the manufacturers publication
e. Remove loop antenna terminal box attaching (table 2-2, HMI Voll). Align the ADF system,
parts. if necessary, in accordance with the manufactur-
f. Disconnect and remove loop antenna cable. ers publication.
Retain spacer washers and rubber gasket for
reinstallation of cable. 2-20. WIRINGDIAGRAM. Seefigurea-l for
Install replacement loop antenna cable in the ADF system interconnection wiring
ff.
reverse order of removal. diagram.
2-5/2-6
CSP
016
lustrarted Parts List

and
FOR
NAV/COMM TRANSCEIVER INSTALLATION

Part No. 369B90071 Basic, 369B90071-503,
3691190071- 507 and 369B90071-509
Hughes He~loopter+ hrm*.Ynn
Issued~ September 1976

COD675180
NI FG I
INTRO
RECORD OF REVISIBNS
CSP-016
MFG REV
$p
NO DESCRIPTION ISSUE DATE DATE BY REMOVED INCOR BY

CSP-Ole Opt Eqpt Manual Table of Contents
NAV/COM TRANSCLdVER INSTALLATION
TABLE OF CONTENTS
Section Page
FOREWORD F,1
F-l, Purpose and Content

of this Manual.......... F-l
F-2, Applicability F-1
F-3, Compatibility of Combined
F-6. Related Publications....., F-l
F-7. Literature Changes
and Revisions F-1
1 ILLUSTRATED PARTS LIST I-I

1-2. Group Assembly
Parts List 1-r
1-3. Illustrations 1-r
2 MAINTENANCE INSTRUCTIGNS 2-1
2-1, General Information...... 2-1

2-2. Description of fat 170A/B
and KX 175B MAV/COM
Transceiver 2-3
Table of Contents
OPC EqpC Manual
CSP-016
NAV/COH rRANSCEIYER IHSTAL~ATION
TABLE OF CONTENTS
Sect~on Page
(CONTINUED)
2-3. Description of
KY 1958 VHF
COMM Transceiver 2-3
2-4. Description of KI 201C
VOR Indicato~,........ 2-3
2-5. Description of KA
39
Voltage Converter 2-3
2-6. Description of
VC 20-30 Coupler 2-3
2-7. Relerence Data 2-3
2-9. Operational Check....... 2-4
2-10. AHgnment 2-4
NAV/COM-COMM
Transceiver...... 2-4
VOR Indicator........ 2-4
2-14. of KA 39
Replacement
VoltageConverter 2-4
2-15. Replacement of VC 20-30
Antenna Coupler 2-6
FOREWORD
F-l. PURPOSE ~JD CONTENTOFTHIS is organized to provide comprehensive coverage

MANUAL. This manual supplements information of entire systems, major equipment groupings,
contained in HMI- Vol 1 and 369D IPC, and and major components that are similar or associ-
instructions for maintenance of the KX 170A/B, ated. Procedures for each of these are presented
KX 175B and KY 195B transceiver installation. in sequence as defined in Section 1, HMI- Vol 1.
This manual also contains parts lists for procur-
ing replacement parts for the KX 170A/B, F-5. USE OF THIS MANUAL. This manual is
KX 175B and KY 195B transceiver equipment. for useby operators of the 369D helicopter
equipped with a KX 1701VB, KX 175B or KY 195B
F-2. APPLICABILITY. The KX1IOA/B, transceiver. Although this manual is a separate
KX 175B and KY 195B transceivers are applicable publication, it should be kept with HMI- Vol 1,
for use on any Hughes 500D (Model 369D) HMI- Vol 2, 369D IPC and other handbooks
helicopter, listed in Section 1, HMI- Vol 1 that form the
primary information file for the helicopter.
lity F-6. RELATED PUBLICATIONS. Referenceis
information on which optional equipment may or made to applicable portions of HMI- Vol 1 and
may not be used in combination at the same time, 369D IPC as required to accomplish instruc-
refer to Section 21, HMI- Vol 1. tions contained herein.
F-4. ORGANIZATION OF CONTENTS. The con- F-7. L;TERATURE CHANGES AND REVISIONS.
tents of this manual are grouped into sections as
outlined in the Table of Contents. Each section are made as defined in Section 1, HMI- Vol 1.
F-1/F-2
SECTION I
and companion illustrations, a complete parts def- replacement parts for the transceiver installa-
inition of the 3691190071 Transceiver (KX 170A/B, tion and shall not be used for any other purpose.
KX 175B and KY 195B) installation, manufactured
by Hughes Helicopters, Culver City, California. 1-3. ILLUSTRATIONS. Ulustrations are pro-
NOTE: The illustrated parts list is organized vided for each group assemblyparts list. Each
and presented in the same manner as the 369D illustration is exploded to the: extent necessary
Series Illustrated Parts List (369D ZPC). (For to show parts relationship for the complete
information on use, refer to the 369D IPC. transceiver installation.
1-1
;d2~
7 I/ i..
..I
D I
it
i
ii
I /=lr~ r
r.3
i
15
17
19
i
i
I) I I
ii.
O i
~s
r) 10-L~
12
i L:
v
i i-
II "-b j1
12
11
~h 2t
~h j
O
1
I/
I
24
\\25~1
3l"f,
j
25
ii ?j
\Y~,e
L_21 O
47-096
Figure 1-1. KX 170A/B, IM 175B, and KY 195B King transceiver and coupler installation
1-2
FIG. UNITS
NO. NO. ASSY
1-1- 3691190071 KX170A/B OR KX175/B TRANSCEIVER SYSTEM 1

INSTL EQPT (See figure 1-2 for further bkdn)
3691190071- 507 KY195/B TRANSCEIVER INSTL EQPT (See figure 1-2 I 1
for further bkdn)
3691190071- 503 1 KX1IOAIB OR KX175/B TRANSCEIVER SYSTEM I 1
PROVISIONS (Part of 369H90071) (See figure 1-2
for further bkdn)
369H90071- 509 1 KY195/B TRANSCEIVER SYSTEM PROVISIONS I 1
(Part of 369B90071-507) (See figure 1-2 for
further bkdn)
-1 369B901~6- 507 1 ANTENNA ASSY (See figure 1-3 for bkdn) I 1
-2 MS51958-61 I.. SCREW 1 2
-3 AN960~10L I.. WASHER 1 2
-4 369H90071-13 1,, STRIP AR
-5 369H90071-7 1,, CLAMP 1
-6 MS51957-33 1,, SCREW 1 3
-7 AN960XC6L I.. WASHER 1 3
-8 MS35338-136 1,, WASHER 1 3
-9 KI%O1C INDICATOR (Part of 3691190071) (See figure 1-2 I 1
for alternate locations)
-10 NAS21043-3 I NUT (Part of 3691190071-503) 2
-11 NAS623- 3-2 1 SCREW(Part of 3691190071-503) 1 2
-12 AN960D10L I WASHER (Part of 3691190071-503) 2
-13 MS25281-3 1 CLAMP(Part of 369H90071-503) 1
-14 AN743-12 I CLIP(Part of 369B90071-503) -I 1
-15 NAS623- 3-5 SCREW 1 2
-16 AN960D10L WASHER...........; 1 2
-17 1 369H90071-5 CLAMP I 1
-18 3691190071-13 STRIP..., i I AR
-19 3691190071-27 1,, FILLER 1 1
-zo KX170A/B OR I NAV/COM TRANSCEIVER SYSTEM (Part of 1
I 1
IM175/B 3691190071)
KY195/B I COMM TRANSCEIVER SYSTEM (Part of I 1
3691190071-507)
-21 AN507- 8R6 I.. SCREW -1 8
-22 369B90071-41 1,, SUPPORT 1 2
-23 2TC13-7. 5 1 CIRCUIT BREAKER I 1
-24 MS21043-3 I.. NUT ;I .1
-25 1 AN960D~OL WASHER 1 .3
_26- 1 AN315- 3R I.. NUT I i
-27;1 MS35338-138 1,, WASHER I 1
-28 F AN960D10 I WASHER I 1
-29 NAS603-9 I SCREW I 1
-30 NASGO1-6 I.. SCREW 1 4
-31 AN960XC6L; I.. WASHER 1 4
32 V(T 20- 30 1- COUPLER I
1-3
Section 1 Opt:EQpt Manual CSP- 010
ii
ii
a
9 3
a"
Y "\i
CQ r, :I LOCATIONS) I
,i o:
c I i
:J ~iuu
LL~/-
c
1Yli
I
I
22
r
21 r 14
12 1
~I
13 11
g Q
;i*
47-097
Figure 1-2. K3Z 170A/B, KX 175B and KY 19~5B King transceiver system converter, indicator
and wire harness installation
11:4
FrG. i I UNTS
NO. NO. ASSY
1-2- 3691190071 KX170A/B OR KX175/B TRANSCEIVER SYSTEM REF

INSTL EQPT (Cont)
369B90071- 507 1 KY195/B TRANSCEIVER SYSTEM INSTL EQPT (Cont)... 1 REF
369B90071- 503 KX170A/B OR KX175/B TRANSCEIVER SYSTEM REF

PROVISIONS (Part of 3691190071)
3691190071- 509 1 KY195/B TRANSCEIVER SYSTEM PROVISIONS I REF
(Cont) (Part of 3691190071- 507)

-1 MS1957-33 I SCREW(Part of 369B90071-503) ........1...... .3
-2 AN960XC6L I WASHER (Part of 3691190071-503) 1 3
-3 MS35338-136 WASHER (Part of 369B90071-503) 3-
KIBO1C I INDICATOR (Part of 3691190071-503) 1 :2
(Alternate locations)
-5 3691190071-13 1.. STRIP AR
-6 NAS623- 2-2 1.. SCREW 1 2
-7 AN960D8L I.. WASHER 2
-8 KA39 I VOLTAGE CONVERTER 1
-9 3691190071-23 1 WIRE HARNESSASSY I 1
-10 MS20470A4 RIVET 1
-11 AN960PD6 I... WASHER 1
-12 SSCBS I... TY-WRAP 1
-13 MS21042- 08 1... 1
-14 AN960PD8 L I ~ASHER 2
-15 111851957-47 1... SCREW 1
-16 MS25281-10 CLAMP 2

-17 097- 0057-33 1~:.... CAPACITOR 2
-18 MS21043-06 I... NUT 1
-19 AN960XC6L i... WASHER 2

-20 NAS601-36 I... SCREW I 1
-21 5607-16 WASHER 2
-22 1707 1... RESISTOR 1
-23 MS20470AD3 I... RIVET 1 2

-24 369H90071-9 CLIP 1 2
-25 369B90071-19 CABLE ASSY (COMM) (Part of 369B90071-50~ 1
-26 d 369B90071-21 i CABLE ASSY CNAV) (Part of 3691190071- 503). ;I ii
1-5
Section 1 Opt Eqpt Manual CSP-D1G
20
n i
Qm
WL
5, 14 17
11
24
~I i
Bi BL \~J ._~ ~I I I 1 i
19.25 &45 W d
LH -CH
0)
1 C
a t7loes
Fi~ure ~i3. ADF/VHF;NAV antenna
1^6
Opt Eqpt Manual section 1
C3P-Ci16
UNITS
FIG.
DESCRIPTION PER
INDEX PART
ASSY
NO. NO.
ADF/VHF NAV ANTENNA INSTL (See figure 1-4 I 1

1-3- 369H90146- 507
for further bkdn)
1 ANTENNAINSTL 1
3691190146- 501
MS21042-3 NUT 4
-1 I
WASHER 4
-2 i AN9 60PD10 L
SCREW 4
-3 NAS603-7P I..
369H9b146-13 CLIP 2
-4
CLAMP 2
-5 MS21919DF4
MS17821-1 I.. STRAP...............; 1
-6
1
-7 NAS625- 3-2 1.. SCREW
1
-8 AN960PD10L I.. WASHER
SCREW 2
-9 NAS623- 3-10
2
_10 APi960PD10L WASHER
ANTENNA 1
-11 VRP-37
1 VARGLAS SILICONE SLEEVING; AR
-12 4
NAS623- 3-2 1.. SCREW 6;
_13
I.. WASHER 1
-14 AN960PD10L
CLAMP 1
-15 MS21919DF4
GROMMET 1
-16 NAS557-4A I..
RIVET............. 5
-17 MS20470AD4
1 BRACKET ASSY I 1
-18 369B90146-15
1... SCREW 3
-19 NAS623- 2-3
WASHER 3
-20 NAS620C8L
1... WASHER 3
-21 5607-18 ,..............i i
1... PLATE 1
-22 3691190146-21
INSULATOR. .I................ 1
-23 3691190146-23
-24 NAS1368N-3A I... GROMMET I 1
,lls7
CSP-OLS
Opt Eript Man~al
Sect~ibn I
I;
I, L-"--" ;2
I I
i: I-I 1 7
lot 1 c
I
2 I~
I 1 3
I I i 5
6 J174B 24
I
1
1~ 1
r,
j j
I I
C:l
;cJ
oi"l^.lo
_J-----~----;,i,j 7
8
1-
I 8
ioi 18
ocJ
~111: ~-!(cJO_ _ _ 14
\~,YCce
SHIP
ii P114A
9 11 i17
ii
1114
P1748
41-688
antenna installation
e~tenbed landing gear
Figure 1-~. pSF/VHF-NA~
1-8
FIG. VNITS
NO. NO. ASSY
1- 4- 369B90146- 507 ADF/VHF NAVANTENNA INSTL(Cont) REF

3691190146-31 1 ANTENNAINSTL I
(Following items used only on helicopters
with extended landing gear installed)
-1 MS25082- C3 NUT I I
-2 I ANgGOD1 OL WASHER 1 4
-3 MS35338-138 WASHER I 1
-4 MS21042-3 NUT I 1
-5 NAS1096- 3-8 BOLT 1 1
-6 MS25281- F3 CLAMP 1
-7 NAS623- 3-3 SCREW 2
-8 AN960PD10L i.. WASHER 2
-9 MS25281- F2 CLAMP 2
-10 MS20470B3 I.. RIVET 4
-11 SO- 107 STANDOFF 2
-12 NAS623- 3-7 SCREW 1 2
-14 VRP-31 ANTENNA
-15 3691190146- 27 1 WIRE HARNESS I 1
-16 UG88/U CONNECTOR....... 2
-17 17 1... LACING AR
-18 RG58/U COAX CABLE I AR
-19 172ALY I... COPPERWIRE AR
CONNECTOR I
-20 UG89/U
-ZI MS20470AD3 I.. RIVET 2
-22 WSI- 4-10 1.. SPACER 1 2
-23 MS35489-11S I.. GROMMET 1
-24 UG89/U I CONNECTOR I
1-9/1-10
SECTION II
2-1. GENERAL INFORMATION. The KX 170A/B a wiring diagram for the NAV/COM- COMM
or installation installation. The maintenance information in this
provides for two-way voice communication be- section pertains to a system already installed in
tween aircraft and with ground stations. The a helicopter. For maintenance information on the
transceiver also receives Very-High- Frequency transceiver, indicator, voltage, converter, and
Omnidirectional Radio Range and Localizer indicator beyond the scope of this manual, refer
(VOR/LOC) for navigation information conversion to the manufacturers publications (table 2-2,
and display. The KY 195 COMM transceiver HMI- Vol 1).
installation provides for radio communications
only. Major components of each system are listed NOTE: The KX 170 and KX 175 vhf NAV/COM
in table 2-1 and described in following paragraphs. installations are essentially identical, except
The KA 39 voltage converter receives +28 vdc for differences in vhf transceivers. Suffix
from the helicopter +28 vdc bus, through the letters for manufacturers model number
NAV/COM 7. 5-ampere circuit breaker on the may vary (example: ICX 170A or KX 170B).
instrument panel, and converts it to +14 vdc at For difference information, refer to para-
approximately 4. 5 amperes power in the trans- graph 2-2. An integrated interphone com-
ceiver and KI 201 indicator. Figure 2-1 provides munication system (ICS) must also be
Table 2-1. Major NAV/COM components
System
Component KX 170A/B KX 175B KY 195B
Transceiver IM 170A/B KX 175B KY 195B
Indicator KI201C KI201C Not used
Voltage Converter KA 39 KA 39 KA 39
Antenna Coupler VC 20-30 VC 20-30 VC 20-30
NAV/COM Antenna VRP 37 VRP 37 Not used
NAV/COM Antenna (used Uses two Uses two Not used

with extended landing gear) VRP 37 VRP 37
antennas antennas
COMM Antenna 369A3014-53 369A3014- 53 369A3014- 53
Antenna Cable Assy 369B90146-27 369H90146-27 Not used
NAV Cable Assy 369B90071-21 3691190071-21 Not used
COM (COMM) Cable Assy 369H9r)071-19 369B90071-19 369B90071-19
Wire Harness 369B90071-23 3 69B9 0071- 2 3 369B90071- 23
2-1
Section 2 Oyt Eql,t Manual ~.::;P-016
NAVICOM
PIO PIO
P171 (RADIO)
~TB501 Fjl*TB101
VHFRADIO +28VDC
t28VDCI 20 KX z s-- P506AM16 --J~ t28 V DC
TRP~NSCLIVLA Rv52an16
(COMMINAV-KING KX 170 OR 7. 5A
TERMINAL (+28 VDC BUS)
KX 175; OR COMM-KING KY 1
030-2102-04 CONNECTOR BOARD
KX1B20 B t28VDC
COMM SWITCHED +28 VDCI 17 KX2A20-------- A ICOMM SWITCHED +28 VDC
AUX AUDIO H3 I 15 t-- KX3A20-----(G GND
w
(NOTE 6)
CROUNDTB 6-2 G GND
NAV 14 VDC INPUT
COMM 14 VDC INPUT
1
18
INSTRUMENT LIGHT DIMMER 1 38~-- KX6B22

KX
KX5A20
PANEL LAMP TERM INAL

BOARD
A
B NAV 14 VDC
COMM 14 VDC
VOLTAGE CONVERTER
i,,
R17 IJJ TB502-8C
KX7A22 PIO (KING KA 39)
SPEAKER OUTPUT 1 41 KX7B22N TB6-2
(KX7A20) 10W GROUND 050-1057-00
(NOTE 4) VHFCOMMRCVR
COMM 500 OHM AUDIO OUTPUT 34 KX8A22 ~1 CONNECTOR
W AUOIO HI DUT INOTE 51
1
NAV 500 OHM OUTPUT 135 KX~A22 NAV IVORILOC) INDICATOR
"TB502-bD PIO
AUX AUDIO X1136 (KING K1 201C) (NOTE 2)
P301
KX6A22 (NOTE 2) E INSTRUMENTLIGHT DIMMER
VORILOC OUTPUT 3 KX10A22 (NOTE 2). D VORILOC INPUT
VORILOC ENERGIZE 4 KXllA22 (NOTE 2) P VOR/LOC ENERGIZE
NAV SW ITCHED 14 VDC 1 26 I-- t- KX12A22 (NOTE 2) C 14 VDC IN PUT
VORILOC COMMON 19~-- tKX13A22(NOTE 2) H VORILOC COMMON
VHF XMIT M IC AU D1O IN
MIC AUDIO IN139 KX14A22 IBLUE)~ (NDTE 5~ TBS02-2B
VHF XMIT MI C
I
MIC KEY IN 40 KX14A22 (RED) KEY (GND) IN
LI
KX13B22 If~ KX 14822N 7h (NOTE 5) PIO
POWER GROUND( 21(L--t- KX15A20N ."TB502-1D P3D1
J LEFT DEFLECTION I
GROUND
~TDEFLECTION I
KX16A22
J174[13691-190146-27(NOTES 2, 7) KX16B22
NAV RF INI P172

RV551A--a
VHF NAV
ANTENNA CABLE
P174
i J174
L~---------otj
/1VHF
ANTENNA
NAV
2200
c~o;
UF,6.3V
(NOTE 2)
(NOTE 2) (NOTES 2. 7)
2200 UF, 6.3V
J175 P102
P523 (NOTE 2)
(RV518A) UHFIVHF VHF COMM
COMM RF I NIOUTIP173C------ RV552A
L
VHF COMM
IRG-581U) ANTENNA
MATCHING
ANTENNA
C;;o;
ANTENNA CABLE IUNIT(COUPLER)
(RG-581U)
(COMM
COMPONENTS
NOTES:
i. ASTERISK INDICATES PART OF HELICOPTER BASIC ELECTR ICAL SYSTEM.
2. USED ONLY WITH KING KX 170 OR KX175. WHEN KING KX 195 IS INSTALLED, VHF NAV ANTENNA
IS NOT INSTALLED AND VHF NAV ANTENNA CABLE AND CONNECTOR P301ARE STOWED.
3. AUWIRING, EXCEPT WIRE NO. P506AM16 AND ANTENNA CABLES, IS PART OF VHF COMINAV WI RING
HARNESS ASSEMBLY.
4. TERMINATION IMPEDANCE USED IN PLACE OF SPEAKER.
5. FOR WIRING INTERCONNECTION INFORMATION, REFER TO INFORMATION ON INTERPHONE SYSTEM AND

RAD IO CONTROL E4U IPMENT IN TH IS OPTION GROU P.
NIINR EPO WARNING SYSTEM, TO ELIMINATE POSSI BILITY OF INTERFERENCE BETWEEN THAT
6. PART OF
SYSTEM AND RADIOIICS SYSTEM.
7, ADDITIONAL VRP-37 ANTENNA AND 369H901/16-27 HARNESS ASSEMBLY USED ON HEL ICOPTERS WITH
EXTENDED LANDING GEAR.
47-101
Figure 2-1, KX 170A/B, KX.175B NAV/COM and KY 195B COMM installations wiring diagram
2- 2
installed in a helicopter for use of the vhf the KA 39 voltage converter. All controls and
NAV/COM installation. The associated indicators are on the face of the unit.
audio components (interphone control unit
or intercom adapter, headset connectors, NOTE: Suffix letter for manufacturers model
headset-microphones, interconnection number may vary (example: KY 195 or
wiring, etc) are required for reception and KY 195B). The King KY 195 or KY 195B vhf
transmission of vhf COMM and reception of COMM transceiver may be used. The KY 195
vhf NAV signals. and KY 195B are basically identical, except
the range of 118. 00 to 135. 95 MHz
frequency
2-2. DESCRIPTION OF KX 170A/B AND KX 175B is covered with 720 channels having 25 kHz
separation for the KY 195B, and with 360
and KX 175B vhf NA~t/COM transceivers contain, channels having 50 kHz separation for the
each in a single panel- mounted unit, a vhf naviga- ICY 195. Both the KY 195 and KY 195B com-
tion(NAV) receiver and a vhf communications ply with specific FAA Technical Standard
(COM) transceiver. The receiver and trans- Order (TSO) specifications. (Refer.to manufac-
ceiver operate independently, using amplitude- turers publications, table 2-2, HMI Vol 1.)
modulated signals. The frequency range of the Otherwise, KY 195 and KY 195B vhf COMM
NAV receiver is from 108.00 MHz to 117.95 MHz, transceivers are directly interchangeable.
tunable in 200 crystal-controlled channels with An integrated interphone system and radio
50-kHz spacing. The NAV receiver receives control equipment must also be installed.
incoming signals from the vhf NAV antenna and The associated audio components (interphone
supplies VOR/LOC navigation information to control unit or intercom adapter, headset
KI201 indicator for visualdisplay. The fre- connectors, headset microphones, etc) are
quency range of the COM transceiver is from required for reception and transmission of
118. 00 MHz to 135. 95 MHz, tunable in 360 vhf COMM signals.
crystal- controlled channels with 50 kHz spacing.
The COM transceiver transmits and receives on 2-4. DESCRIPTION OF KI 201C VOR INDICATOR.
the same frequency, using the uhf/vhf antenna. The KI 201C VOR indicator operates using demod-
Output power of the transistorized transceiver is ulated signals from the NAV receiver to provide
5 watts minimum into a 50-ohm load. The unit visual display of VOR (omni) and LOC (localized)
operates on +14 vdc supplied through the KA 39 information. The KI201C indicator converts this
voltage converter. All operating controls and information into de voltages which drive the
indicators are on the face of the unit. LEFT- RIGHT needle and the TO-OFF- FROM
flag on the face of the indicator. The Omni Bear-
NOTE: The King KX 170A, KX 170B or ing Selector (OBS) knob is used to manually
KX 175B vhf NAV/COM transceiver may rotate and position the coarse index card.
be used. The KX 170A and KX 170B vhf
transceivers are basically identical, except 2-5. DESCRIPTION OF KA 39 VOLTAGE CON-
the frequency range of 118. 00 to 139.95 MHz VERTER. The KA 39 voltage converter consists
is covered with 720 channels having 25 IdIz of dual series regulators that convert 28 vdc to
separation for the KX 170B, and with 360 14 vdc. One regulator supplies operating power
channels having 50 kHz separation for the to the NAV receiver, the other supplies power to
KX 170A. The KX 175B is identical to the the COM (COMM) transceiver.
KX 170B, except the KX 175B also complies
with specific FAA Technical Standard Order 2-6. DESCRIPTION OF VC 20-30 COUPLER.
(TSO) specifications. (Refer to manufac- The
turers publications, table 2-2, HMI- Vol i.) antenna coupler is connected in series in the COM
Otherwise, IM 170A/B and KX 175B vhf (COMM) antenna cable, and is used to match im-
transceivers are directly interchangeable. pedance of antenna and transceiver.
2-7. REFERENCE DATA. Information on heli-

2-3. DESCRIPTION OF KY 195B VHF COMM copter systems that interface with the NAV/COM-
s- COMM system is in HMI Vol 1 and 369D TPC.
ceiver transmits and receives amplitude-modulated For information on associated optional avionics
voice signals in the frequency range from 118. 00 equipment used with the NAV/COM- COMM system
MHz to 135.95 MHz. Dual, independent frequency (such as the integrated interphone communication
selectors provide switch selection of either one or system (ICS) and the KI 211C ILS indicator),
refer
two previously chosen frequencies. The COMM to theapplicable Opt Eqpt Manual for that specific
transceiver operates on +14 vdc supplied through equipment (Section 21, HMI- Vol 1).
2-3
Section 2 Opt Eqpt Manual CSP-O1B
2-8. TROUBLESHOOTING, If the NAV/COM- would reduce the COMM receiver sensitivity by
COMM system doesotoperate properly during increasing the squelch threshold.
operational check or normaluse, refer to table (4) Verify communications capability at
2-2 for aid in locating the probable trouble and both the high and low ends of the vhf COMM band.
for corrective action. Refer to the NAV/COM-
COMM wiring diagram (tig. 2-l).for aid in 2-10. ALIGNMENT. Refer tothe manufacturers
troubleshooting. If troubleshooting indicates that HMI- Vol 1) for instruc-
the trouble is in the VOR indicator or the NAV/ tion for aligning the NAV/COM- COMM system.
COM- COII~M transceiver, refer to the manufac-
turers publication (table 2-2, HMI- Vol 1) for 2-11. INSPECT~N. Inspect components of the
unit troubleshooting and corrective action. in accordance with
FAA AC 43. 13-1A and standard avionics mainte-
NOTE: The audio is
reproduced by compo- nance practices, and the following:
nents of the integrated interphone communi- a. Inspect all components for obvious physical
cation system (ICS) which, in itself, may be damage, corrosion and evidence of electrical
the source of audio trouble. When audio overheating.
malfunction is encountered, refer to the ICS b. Inspect the VOR indicator and NAV/COM-
Opt Eqpt Manual (table 21-1, HMI- Vol 1) C07MM transceiver for loose or missing control
for troubleshooting procedures for that knobs, damaged or obscured markings, and loose
portion of audio circuitry. or damaged connectors.
c. Inspect the wire harness assembly and

2-9. OPERATIONAL CHECK. Thefollowing antenna cable for cuts and other damage, loose
procedure is used to verify the capability of the connectors or connecting hardware, and frayed
NAV/COM- COMM system to function correctly. insulation.
The procedure should ke performed anytime a
malfunction is suspected, and prior to normal 2-12. REPLACEMENT OF NAV/COM-COMM
use after repair. TRANSCFZVER.
a. NAV/COM transceiver: a. Check that all electrical power is OFF.
(1) Maintain an appropriate altitude and b. Remove instrument panel side fairings
contact a ground station facility at a range of at (Section 17, HMI- Vol 1).
least 50 nautical miles, c. Disconnect the electrical connector (part of
(2) Contact a nearby ground station. w~e harness assembly; 9, fig. 1-2) at rear of
(3) Set the OFF/ON/TEST switch to TEST transceiver (20, fig. 1-1).
and listen for any unusual electrical noise that d. Remove screws (15), washers(l6), clamp
would reduce the COM receiver sensitivity by (lt), and strips (18).
increasing the squelch threshold. e. Carefully remove transceiver (20).
(4) Verify communications capability at f. Install the replacement transceiver in
both the high and low ends of the vhf COM band. reverse order of removal.
(5) Select a VOR frequency for a transmit-

ter within 40 nautical miles range and listen to 2-13. REPLACEMENT OF VOR ZNDICATOR.
the VOR audio to ensure that no electrical inter- a. Check that all electrical power is OFF.
ference is present, b. Remove instrument panel side fairings
(6) Check the tone identifier filter (Section 17, HMI- Vol 1).
operation. _c. Removescrews (2, fig. 1-I), washers (3),
(7) Fly inbound or outbound on a selected clamp (5), and strips (4).
VOR radial and check for proper LEFT-RIGHT d. Remove screws (6), washers (7, 8) and
and TO-FROM indications. Check VOR accuracy. indicator (9).
e. Install the replacement indicator in reverse
NOTE: At low altitudes, VOR ground station order of removal.
scalloping may be present.
b. COMM transceiver: 2-14. REPLACEMENT OF KA 39 VOLTAGE

(1) Maintain an appropriate altitude and CONVERTE~
contact a ground station facility at a range of at a. Check that all electrical power is OFF.
least 50 nautical miles. b. Remove screws (6, fig. 1-2), washers (7),
(2) Contact a nearby ground station. and voltage converter (8).

(3) Set the OFF/ON/TEST
switch to TEST c. Install replacement voltage converter in
and listen for any unusual electrical noise that reverse order removal.
2-4
Table 2-2. Troubleshooting i
Symptom Probable Cause Corrective Action
KX 170A/B OR KX 175B NAV/COM TRANSCEIVER INSTALLATION
Radio and indicator NAV/COM circuit breaker Set circuit breaker to ON.
inoperative (23, fig. 1-1) not ON.
No de power on helicopter Refer to Section 19, HMI- Vol 1.

main bus.
Disconnected or damaged Connect, repair, or replace wire

wire harness assembly. harness assembly, as required.
Defective voltage converter. Replace voltage converter.
NAV/COM circuit Overload or short circuit. Set circuit breaker to ON. If trip
breaker trips reoccurs, replace overloaded or
shorted component.
NAV voice ok, indica- Defective indicator. Repair or replace indicator.

tion erroneous
Defective NAV receiver. Repair receiver or replace

transceiver.
Disconnected or damaged Connect antenna cable or repair

NAV antenna antenna, as required.
No NAV voice received, Defective COM receiver. Repair or replace transceiver.

indication ok
Disconnected NAV antenna or Connect antenna cable or repair
damaged antenna. antenna, as required.
Damaged or defective antenna Replace antenna coupler.

coupler.
KY 195B COMM TRANSCEIVER INSTALLATION
Both transmitter and NAV/COM circuit breaker Set circuit breaker to ON.
receiver inoperative (23, fig. 1-1) not ON.
No de power on helicopter Refer to Section 19, HMI Vol 1.

main bus.
Disconnected or damaged Connect, repair, or replace wire

wire harness assembly, harness assembly, as required.
Defective voltage converter. Replace voltage converter.
NAV/COM circuit Overload or short circuit. Set circuit breaker to ON. If trip
breaker trips reoccurs, replace overloaded or
shorted component.
No reception of audio Defective COMM receiver. Repair receiver or replace

at any stat-ion; ICS oper- trans ceiver.
ation ok, transmit ok
2-5
:-~ction 2 Opt Eqpt Manual CSP-016
Table 2-2. Troubleshooting (cont)
symptom Probable Cause Corrective Action
KY 195B COMM TRANSCEIVER INSTALLATION (CONT)
Cannot transmit; Defective COMM transmitter. Repair or rel,lacc~ Irnnsmitter.

ICS operation ok,
reception ok
Cannot receive or Defective COMM transceiver. Repair or replace transceiver.

transmit; ICS
operation ok Disconnected or damaged COM Connect antenna (;lble or repair
antenna, antenna, as required.
Damaged or defective antenna Replace antenna coupler.

coupler.
2-15. REPLACEMENT OF VC 20-30 ANTENNA 2-17. REPAIR. Refer to Section 19 of HMI

Vol 1 for electrical repair in~tructions. Replace
a. Open plenum chamber access door damaged cable clips and otl ~r attaching hardware
(Section 2, HMI- Vol 1). with new parts. When
a malfunction occurs in the
b. Remove nuts(24, 26, fig. 1-1), washers NAV/COM- COIMM transceiver or VOR indicator,
(25, 27, 28), and screw (29). replace parts found to be defective by the trouble-
c. Remove screws (30), washers (31), and shooting procedures provided in the m:~nufac-
antenna coupler (32). turerrs publication (table 2-2, HMI- Vol 1).
d. Install replacement antenna coupler in Align the NAV/COM- COMM system, if necessary,
reverse order of removal, in,accordance with the manufacturers
publication.
2-16. ADJUSTMENT. Refer to the manufac-
2-2, HMI Vol 1) for 2-18. WIRING DIAGRAM. See figure 2-1 for the
adJustment procedures for the NAV/COM-COMM NAV/COM- COMM system interconnection wiring
transceivers. diagram.
2-6
CSP
017
Illustrated- Parts List

and
FOR
INTEGRATED INTERPHONE SYSTEM (ICS) INSTALLATION

Part No. 3691190066-11
USED ON HUGHES 50011 (MODEL 369D) HELICOPTERS
Hughes HBlioopten ..mn*
Issued 15 August 1976

COD671070
NI FG.
INTRO
BECORD OF REVISIONS
CSP-017
MFG REV
I~a
ATP RE1 INSERT DATE REV REMOVE
REV NO
CSP 017 Opt Eqpt Manual Table of Conbnt
INTEGRATED INTERPHONE SVSTEM
TABLE OF CONTENTS
Section Page
FOREWORD F-1
F-r. Purpose and Content

of this Manual........ F-l
F-3. Compatibility of Com-
bined Optional
Equipment,.......,. F-l
F-4. Organization of
Contents F-I
F-5. Use of this Manual..... F-l
and Revisions F-l
Scope and Contents,.... 1-1

List.,............. I-1
1-3. Illustrations .,.......1-1
2 MAINTENANCE INSTRUCTIONS. 2-1
2-1. General InIormation.... 2-1

2-2. Description........ 2-1
2-3. Reference Dala..~.... 2-2
2-4. Inspection, ..........2-2
2- 5. Troubleshooting- ICS
System........... ..2-2
T~ble d Content
CSFO11 Opt Eqpt M;u~ual
INTEGRATEO INTERPHOHE SYSTEM
TABLE 06 CONTENTS
Section Page
2 I\-IAINTENANCE INSTRUCTIONS
(CONTWUED)
2-6. Carter CE 500 HT-3G ICS

Amplifier ~Interphone
Control Unit).......... 2-2
2-7. Troubleshootlng- Inter-
phone (ICS) Control Unit... 2-6
2-8. Testing- Interphone (ICS)
Control Uni~.........2-8
2-9. Replacement- lnterpnone
Control Unlt......2-6
2- 10. Headset Switch and Jack
Assembly 2-6
2-11. Headset-Microphones 2-17
2-12. Pilots Headset Jack 2-17
2-13. COMM 1-XMIT-COMM 2
Radio Selector Switch
Assembly........... 2-17
2- 14. Ad)ustment of Intercom
Microphone Audio Level
(Integrated Interphone
System) 2-17
2-15. Adjustment of VHF COMM
Receiver-Transmitter
Sldetone Level (Integrated
Interphone System) 2-18
2- 16. Adjustment of Intercom
Pnone Audio Level Inte-
grated lnterphone System
(Control Unit)..~....... 2-18
FOREWORD
F-l. PURPOSE AND CONTENT OF THIS of entire systems, major equipment groupings
MANUAL. This manual supplements informa- and major components that are similar or asso-
tion contained in HMI Vol 1 and 369D IPC, ciated. Procedures for each of these are
and contains instructions for continuing main- presented in sequence as defined in Section 1,
tenance of the 369B90068-11 integrated inter- HMI Vol 1.
phone communication system (ICS). This

manual also contains parts lists for procuring F-5. USE OF THIS MANUAL. This manual is
replacement parts for the integrated interphone for use by operators of the Model 369D helicopter
system. equipped with the integrated interphone system.
Although this manual is a separate publication,
F-2. APPLICABILITY. Theintegratedinter- it should be kept with HMI Vol 1, HMI Vol 2,
phone system is applicable for use on any Hughes 369D IPC and other handbooks listed in Sec-
500D (Model 3691)) helicopter. tion i, HMI Vol 1 that form the primary
information file for the helicopter.
OPTIONAL EQUIPMEN~ For compatibility
F-6. RELATED PUBLICATIONS. Referenceis
information which optional equipment may or may Vol 1 and
made to applicable portions of HMI
not be used in combination at the same time, 36933 IPC as required to accomplish instructions
refer to Section 21, HMI Vol 1.
contained herein.

sections F-7. LITERATURE CHANGES AND REVISIONS.
as outlined in the Table of Contents. Each section Changes and revisions to contents of this manual
to provide comprehensive made as defined in Section 1, HMI Vol 1.
is organized coverage are
F-1/F-2
SECTION I
1-1. SCOPE AND CONTENTS. This illustrated 1-2. GROUPASSEMBLYPARTS LIST. The
and companion illustrations, complete parts replacement parts for the integrated interphone
definition of the 369B90068-11 Integrated Inter- system, and shall not be used for any other
phone System manufactured by Hughes Helicop- purpose.
ters, Culver City, California.
1-3. ILLUSTRATIONS. Anillustration (fig. 1-1)
NOTE: The illustrated parts list is organized is assembly parts list. The
and presented in the same manner as the 369D exploded to the extent necessary to
illustration is
Series Illustrated Parts List (369D IPC). (For show parts relationship for the complete integrated
information on use, refer to the 369D IPC. interphone system.
1-1
~a I
9
i
lo
P,:
h-r---7 L/
c~
O RO TATE
ii i I:\
i~I!i
~r:
3i,;
I I i
~J
I
i
3
I I
ii..
7
//j j1~- 1
I
c/\ ij i
"-lb
i;
1
iIc 8 O
47-050
Figure 1-1. Integrated interphone (ICS) system installation
1-2
FIG. UNITS
NO. NO. ASSY
1-1- 369B90068-11 INTEGRATED INTERPHONE SYSTEM INSTALLATION.. REF

369H92042 HEADSET (Not supplied; must be purchased REF
separately)
369H92492-11 SWITCH AND JACK ASSEMBLY (Not supplied REF
with kit and must be purchased separately)
-1 2TC13-7-5 CIRCUIT BREAKER 1
-2 NAS1635-3-7 SCREW 4
-3 AN960C 10 L WASHER 4
-4 369B6426-3 INTEGRATED INTERPHONE SYSTEM I 1
CONTROL UNIT (Calxter CE 500 HT-JG
ICS amplifier) (Instaled with 369H94011-81
as a set only)
-5 MS35206-227 SCREW 2
-7 369N92477-11 HARNESS ASSEMBLY 1
-8 369B94001-101 HARNESS ASSEMBLY(Left hand) 1
369H94001-91 HARNESS ASSEMBLY(Righthand) 1
-9 369B94001-71 HARNESS ASSEMBLY 1
-10 369B94001-81 1 HARNESS ASSEMBLY 1
1-3/1-4
SECTION II
2-1. GENERAL INFORMATION. The integrated Avionics Equipment (cont)

interphone communication system and radio con-
trol equipment (ICS system) (fig. 1-1) provides Dual vhf communi cations/navigation
selection and control of intercom or vhf radio GCOMM/NAV) installations
operation and permits monitoring received audio Automatic direction finding (ADF) installations
signals from any installed vhf COMM 1 and/or
COMM 2 radio installation, vhf NAV installation Distance measuring equipment @ME)
and/orautomatic direction finding (ADF) radio installation
equipment. The interphone system also contains Air traffic control radar beacon transponder
provisions for an auxiliary audio input for use
installations
with any other optional audio source. The inter-
phone system functions with or without radio Public address (PA) sound and siren system
equipment installed. The equipment provides installations
two-way interphone communications between
the pilot and all passengers at the intercom 2-2. DESCRIPTION. (Seefigure 1-1.) Individual
stations and permits personnel at all stations to provided for the pilot
are
monitor received radio signals. In addition, the and copilot in the pilots compartment, and one
pilots and copilots radio/intercom stations may intercom station is furnished for each of the two
select and use radio transmission for a vhf passengers in the passenger compartment and the
COMM 1 radio and/or a vhf COMM 2 radio passenger in the pilots compartment. A headset
(if installed). switch and jack assembly, containing a radio-
interphone (RADIO-ICS) switch, is used at each
NOTE: Although 369H92042 Headset- station, except the pilots position where a
Microphones are not supplied with the ICS RADIO-ICS switch on the cyclic stick is used for
system, coverage is included in this manual selection of operation desired. The headset jack,
for headset-microphones, Also coverage is RADIO-ICS switches, and headset switch and jack
supplied in this manual for 369H92492-11 assemblies are as described in paragraph 2-10
Switch and Jack Assemblies. Several op- except the RADIO-ICS switch on the assembly
tional avionics installations may be used selects only ICS operation at the ICS switch posi-
with the ICS system; these installations may tion for the front center and two rear intercom
include communications (COMM), navigation stations. The XMIT position on the RADIO-ICS
(NAV), ADF and other similar types of equip- switch at the pilots and copilots radio intercom
ment, including those listed at the end of this stations selects vhf radio transmit operation. A
note. For information on any optional vhf Carter CE500HT-3G integrated interphone system
COMM, high frequency (hf) COMM, vhf NAV control unit (para 2-6) contains microphone filter-
or ADF radio installation that is installed ing, audio amplification, switching and control
and used with the ICS system, refer to the circuits and interconnects the headset-jacks,
applicable Opt Eqpt Manual (Section 21, switches and associated avionics equipment.
HMI Vol 1) for that specific equipment. Five Carter CEH157-H-V headset-microphones
(para 2-10) are used with the interphone system.
Avionics Equipment A COMM 1-COMM 2 XMIT switch is provided for
selection of vhf COMM 1 or COMM 2 radio equip-
Four- or five-station interphone systems ment operation (if installed). Wire harness
assemblies interconnect the interphone system
Hf SSB communications (COMM) installation
components. A 7. 5-ampere NAV/COM circuit
Vhf communications (COMM) installations breaker CB108 protect~ the interphone system and
vhf radio equipment from circuit overloads. A
Vhf navigation (NAV) installations
schematic diagram of the interphone and asso-
Vhf communications/navigation (COMM/NAV ciated radio control circuits for a typical (pilots)
installation intercom station is shown in figure 2-1.
2-1
NOTE: Interconnection wiring for the equip- interconnection and master control for all inter-
ment is shown in figure 2-2. Headset switch com audio and radio
keying, control and audio
and jack assemblies and headset-microphones circuits. Microphone audio is amplified by the
are not furnished with the ICS system but are unit for intercom operation or switched directly
available separately. (Refer to parts list in to the associated vhf radio (when used) without
Section i. amplification for radio transmission. The con-
trol unit sidetone audio from vhf
amplifies
2-3. REFERENCE DATA. Informationonheli- COMM 1 COMM 2 radio equipment (when used)
or
with the CS for application to headphones during vhf radio
system is in HMI Vol 1 and 369D IPC. For transmission. Transistors are used in the unit
information associated optional avionics
on for microphone preamplifier, microphone ampli-
equipment used with the ICS system, refer to the fier and sidetone amplifier circuits. The final
applicable Opt Eqpt Manual for that specific audio amplifier is an integrated circuit (IC). The
equipment (Section 21, HMI Vol i). control unit is installed in the lower right forward
area of the instrument console (fig. 2-3). A
2-4. INSPECTION. (See figures 1-1, 2-1, 2-2 removable the control unit provides
cover on
and 2-3.) Inspect integrated interphone systems access to internal components on circuit boards.
components in accordance with FAA AC 43. 13-1A An internal schematic diagram for the control
and aircraft standard.electrical repair and unit is shown in figure 2-4. The control unit
replacement practices and procedures, noting functions as follows.
the following: a. ControlUnit Circuits. Microphone audio
circuitsinthe control unit are used for both ICS
CAUTION: Ensure all electrical power to operation and vhf COMM radio transmission.
system is OFF. Microphone amplification circuits amplify
audio
microphone only for ICS operation. ICS
audio
a. Examine wiring harnesses for damage; and keying circuits control routing of amplified
wire terminals and terminal boards for security microphone audio signals for intercom use.
of attachment. Transmit keying circuits control routing or
b. Examine control unit for good electrical microphone audio for radio transmission. Side-
bond to instrument console structure (Section 19, tone audio amplification circuits amplify radio
HMI Vol 1). transmitter sidetone audio signals during vhf
c. Examine connector plug pins for looseness, radio transmission. A phone audio amplifier
bends or corrosion. amplifies receiver audio signals during radio
reception; microphone audio during interphone
2-5. TROUBLESHOOTING ICS SYSTEM. Refer operation; and sidetone audio at radio transmis-
to sion. An internal de voltage regulator Q1 regu-
Use applicable portions of the information for lates de voltage for external microphones and
equipment installed. See applicable wiring amplifier circuits in the unit. The following
diagrams at the end of this manual for complete information briefly describes operation of
interconnection wiring information. Use sche- circuits.
matic diagrams and other related data in this b. Microphone Audio Circuits. During ICS
manual as necessary. Where appropriate, use operation, microphone audio signals, from an
applicable Opt Eqpt Manuals for associated intercom station, are applied through resistance-
optional avionics installations and equipment capacitance (RC), input impedance matching,
(Section 21, HMI Vol 1). voltage dropping and coupling components and
ICS microphone audio level control R8 to the
NOTE: A trouble in one installation may affect input of microphone preamplifier 02. When
a function of another installation when installa- pilots or copilots station is used, signals also
tions use equipment in common or function pass through normally closed contacts of either
with equipment of related installations. This pilots or copilots transmit relay (K2 or K3), as
especially applies to intercom and vhf radio applicable. ICS control R8 adjusts level of
control equipment and associated radio microphone audio signal applied to microphone
installations. audio preamplifier and controls microphone
amplifier 03 audio output signal level. The pre-
2-6. CARTER CE 500 HT-3G ICS AMPLIFIER amplifier and series-connected microphone
amplifier amplify microphone audio signal for
2-3 and 2-4.) The ICS control unit is a solid application to the phone audio amplifier. When
state device containing audio filtering, amplificrt- ICS keying circuit (e below) operates, ICS relay
tion, switching, radio transmitter keying and K1 energizes to close contracts K1-A and apply
controlcircuits. The control unit is the common amplified microphone audio signals to phone
2-2
Section 2
CSP- 017 Opt Eqpt Manual
Table 2-1. Troubleshooting ICS system
Probable Trouble Corrective Action

Symptom
WARNING: Before removing or installing components connected to the electrical system,

ensure that all electrical power is OFF. If units are not immediately replaced, ensure that
all electrical connectors are suitably capped and stowed and all loose cable ends are properly
insulated to prevent the possibility of shorting. Serious injury or death could result from
voltages present in the electrical system.
NOTE: Following general troubleshooting information also applies to other avionics installa-
installation
tions that may be installed in the helicopter, since a trouble in equipment in one
that is commonly used by other installations can cause a symptom with associated installa-
tions. Disregard information that pertains to equipment or installations that are not installed.
GENERAL
of Defective associated circuit Replace affected circuit breaker.

No de power to equipment an
installation breaker
No de power on helicopter Refer to Section 19, HMI Vol 1.

main de bus
Circuit breaker trips Overload or short circuit in Isolate to the specific installation;
equipment of associated then troubleshoot the installation.
installation
NOTE: A single circuit breaker ti~at is part of a specific installation may also be used for
other installations. Be sure to check all installations that can affect the circuit breaker.
Identical trouble symptom com- Defective equipment in one Isolate defective equipment to
mon to two or more installations installation that is also used the applicable installation; then
by other installation(s) troubleshoot the installation.
Trouble isolated to one function Faulty terminal block con- Check and repair connection
or location nection or wiring in affected or wiring.
circuit
Lamp filament Replace lamp in affected unit.

Panel lamp does not light open
NOTE: troubleshooting other avionics installations for audio troubles, or other

Before
first
functions that are dependent upon intercom and vhf radio control equipment, be sure to
check that intercom and vhf radio equipment functions correctly. Troubles that may occur
in intercom and vhf radio control equipment that affect radio operation are listed
in the
following troubleshooting procedures for intercom and vhf radio control equipment. Also,
troubles that may occur in equipment or other installations that affect intercom and radio
operation are listed in these procedures.
INTERCOM AND RADIO CONTROL EQUIPMENT
NOTE: Station in following procedures refers to radio/intercom station in the helicopter.

unit
A separate table 2-2 in this manual provides input and data for the interphone control
for troubleshooting the unit.
PA, SSB or RADIO circuit Overload or short circuit in Repair or replace control unit.
breaker trips interphone control unit
2-3
Opt Eqpt Manual CSP-O11
Section 2
Table 2-1. Troubleshooting ICS system (cont)

SSlmptom
INTERCOM AND RADIO CONTROL EQUIPMENT (CONT)
Repair replace control unit.

Radio and ICS modes of operation Defective interphone system or
are inoperative at all stations control unit
Cannot transmit audio from one Defectivemicrophone in Repair or replace headset-
station to any other station; headset-microphone microphone.

normal ICS and radio operation
from other stations Defective associated Repair or replace switch.
RADIO-ICS switch
Defective headset in Repair or replace headset-

Cannot receive interphone and
receiver audio at one station; headset-microphone microphone.
normal ICS and radio operation
at other stations
Cannot transmit and receive Defective interphone (ICS) Repair or replace control unit.
audio between any stations for keying circuit in interphone
ICS operation; radio transmis- control unit
sion and reception normal at
all stations Defective microphone audio Repair or replace control unit.
circuit or amplifier in
interphone control unit
Defective audio circuits in Repair or replace vhf COMM

vhf COMM radio associated radio.
with intercom control unit
Cannot transmit radio signals Incorrectly adjusted ICS Adjust control as necessary.
and cannot transmit and receive control RE on interphone
audio between any stations; control unit
radio reception normal at all
stations Defective microphone filter Replace microphone filter.
Defective microphone audio Repair or replace control unit.

circuit or amplifier in inter-
phone controlunit
Cannot transmit and receive Defective phone audio Repair or replace control unit.
audio between any stations and amplifier circuits in
cannot receive radio signals; interphone control unit
radio transmission normal at
all stations Defective audio circuits Repair or replace vhf COMM
in vhf COMM radio radio.
Defective radio equipment in Repair or replace defective radio

Cannot transmit or receive
radio signals; ICS operation associated radio installation equipment.
normal between stations
Defective interphone control Repair or replace control unit.
unit
2-4
Table 2-1. Troubleshooting ICS system (cont)
INTERCOM AND RADIO CONTROL EQUIPMENT (CONT)
Cannot transmit radio signals; Defective audio circuits in Repair or replace vhf COMM
can receive radio signals and vhf COMM radio radio.
ICS operation is normal at
stations Defective transmit (XMIT) Repair or replace control unit.
keying circuit in interphone
control unit
Cannot receive radio signals; Defective audio circuits in Repair or replace control unit.
radio transmission and ICS interphone control unit
operation normal at stations
Defective receiver in Repair or replace radio.
associated radio
No transmitter sidetone audio Incorrectly adjusted COMM 1 Adjust applicable control as

at any station during radio (or COMM 2) sidetone level necessary.
transmission; otherwise, control R22 (or R25) on
ICS, radio transmission and interphone control unit
radio reception normal
Defective sidetone audio Repair or replace control unit.
circuits or amplifier in
interphone control unit
Defective sidetone circuits Repair or replace vhf or hf COMM

in associated vhf or hf radio.
COMM radio
audio amplifier Q4 below). The phone amplifier connected and closed contacts of K2-B and K3-B
further amplifies microphone audio signals which of pilots and copilots transmit relays, to ICS
are then routed, through output transformer T1, relay K1 energizing ICS relay K1; closing relay
to common phone hi audio line for distribution to K1-A contacts and applying amplified microphone
headset earphones of headset-microphones at all audio signals from output of the microphone
intercom stations. During radio transmission, amplifier to input of the interphone audio ampli-
pilots (or copilots) microphone audio signal is fier (b above). (Diode CR7 across ICS relay K1
routed through contacts of energized pilots (or ensures correct activation of the relay and the
copilots) transmit relay to transmitter of vhf relay is protected by resistor R42.

COMM radio transceiver, instead of microphone d. Receiver AudioCircuits. Receivedaudio
preamplifier. (Refer to e below.) During radio (if installed)
transmission, pilots (orcopilots) microphone are routed
through impedance matching and
audio signals are not amplified prior to applica- terminating resistors to input of phone audio
tion to radio transmitter. Microphones are sup- amplifier for amplification and distribution to
plied operating voltage through voltage regulator headsets at intercom stations below). When
Q1 incl~iding voltage regulator VR1 and series- received, receiver audio signals are amplified
connected and voltage-dropping 010-ohm resistors by phone amplifier and routed to headsets at all
from cathode of voltage regulator VR2. OToltage intercom stations during both ICS operation and
regulators are zener diodes. radio transmissions.
c. ICSKeyingCircuits. WhenaRADIO-ICS e. TransmitKeyllng Circuits. Whenpilots
switch at one of the intercom stations is depressed (or copilots) RADIO-ICS switch is depressed to
to ICSposition, an ICS keying control signal XMIT position, a transmit keying control signal
(ground) is applied through a diode, and series (ground) is applied to pilots transmit relay K2
2-5
(or copilotstransmit relay K3), as applicable, in maintaining a steady de supply voltage for
When relay K2 or K3 energizes, contacts K2-B microphone audio preamplifier, audio amplifier
(or K3-B) open and the path for lCS keying ground and microphones. Pilots and copilots transmit
is opened, disabling ICS keying circuits (e above). relays K2 and K3 and ICS relay K1 operate
The transmit keying ground is also simultaneously directly front +28 vdc, independent of voltage
applied through diode CR13 (or CR14) to trans- regulator.
mitter of vhf COMM radio transceiver to activate
radio transmission. When transmit relay ener- 2-?. TROUBLESHOOTING INTERPHONE (ICS)
gizes, radio transmit audio circuits are also CONTROL UNIT. See figure 2-4 and refer to
enabled (f~ below). Diodes CR5 and CR6 across table 2-2 for input and output signals for inter-
transmit relays K2 and K3 ensure correct opera- phone control unit and also refer to table 2-1 for
tion of relays. troubleshooting the overall ICS system.
f. Radio Transmit Audio Circuits. When radio
the pilots 2-8. TESTING INTERPHONE (ICS) CONTROL
transmit relay K2 (or copilots transmit relay K3) UNIT.
is energized (e above). When the relay energizes, a. Connect a 100-ohm ~5 percent, a-watt
relay K2 (or K3) also closes contacts K2-A (or resistor between PHONE HI and PHONE LO pins
K3-A) that switch associated microphone audio of connector 5509 on systems control unit.
signal from the input of microphone preamplifier b. Apply 28 10. 5 vdc to +28 vdc and -28 vdc
and route it to vhf COMM radio transceiver for (GROUND) pins of connector 5509; comply with
radio transmission. (Microphone audio signals polarity requirements (takle 2-2).
are not amplified prior to application to the radio c. Connect an ac voltmeter between PHONE HI
transmitter. and PHONE LO pins of connector J509.
g. Sidetone Audio Circuits. During radio d. Continue testing control unit as indicated in
transmission, sidetone audio signals from trans- table 2-2.
mitter of vhf COMM transceiver are applied
through impedance matching resistor; a
an 2-9. REPLACEXIIENT INTERPHONE CONTROL
COMM 1 sidetone level adjustment control R22 UNIT. (See figure2-3.) For installation of com-
and coupling components to sidetone amplifier, ponentst refer to Section 3. For removal,
COMM 1 control R22 adjusts the level of sidetone reverse procedures.
audio signal applied to input of sidetone amplifier.
After amplification by sidetone amplifier, the NOTE: If control unit is not to be replaced,
amplified sidetone signal is further amplified by do not disturb the setting of external and
phone amplifier and applied to phone hi line, COMM 1 and COMM 2 sidetone level controls
through output transformer T1, for distribution onthe side of the unit when removing control
to headsets at all intercom stations (h below). unit.
A second identical sidetone input circuit, except
with a COMM 2 controlR25, is furnished that 2-10. HEADSET SWITCH AND JACK ASSEMBLY.
operates in the same manner for a second vhf A headset switch and jack assembly is furnished
COMM radio (if installed), at all stations used (fig. 1-1), except the pilots
h. Phone Audio Amplifier. Phone audio ampli- position. The RADIO-ICS switch on the pilots
fier audio signals cyclic stick grip is normally used for selection
and radio transmit sidetone signals. In addition, of radio transmission, in addition to selection of
phone audio amplifier further amplifies micro- radio reception or interphone operation. The
phone audio signals between intercom stations headset switch and jack assembly (switch/jack)
during interphone operation. Resistor R11 deter- is used for selection of radio reception and inter-
mines gain of the amplifier for amplification to phone operation. At customer option, the avionics
desired level. Amplified audio output signal from installation wiring may be interconnected to pro-
phone amplifier is coupled through output trans- vide selection of radio transmission as well as
former T1 to phone hi audio line for distribution radio reception and interphone. The switch/jack
to earphones in headsets at all intercom stations, consists of a switch and jack assembly case with
i. DC Voltage Regulator Circuits. Transistor an attached coiled cord. The case contains a
Q1 functions as a de voltage regulator to maintain RADIO-ICS switch and a headset jack. A headset
a constant de voltage source for external micro- connector is attached to the free end of the coiled
phones and all amplifier circuits in the system. cord. The headset connector mates with a Iwlk-
Zener diode VR1 maintains a steady de bias volt- head mounted headset connector. A clil, is pro-
age for base of transistor Q1. Internal resistance vided on the side of the case for attachm:~;ll to
of and current conduction through Q1 varies with clothing. The headset jack is a
amplifier circuits de loads to maintain a stable de phone jack and mates with a standard U- L7~/U
voltage at emitter of Q1. Zener diode VR2 assists phone plug for connection to a headset. II,(
2-6
KRe5-llA22--TB6-2 (SHIELD
TB502-8 1 TB502-1
TB501 ADF RECEIVER (KING KR 85) --CbC, I A ~--1533B22 --TB502-7F P509-dd---CNS12B22 A

VHF NAV RADIO (RCA-AVN-211)- -----P503-12- -CNS62A22- --7 B -L533ELO --TB105-4 (NOTES B COMM XMIT KEY
NOTES: 1.i 1, 2)
171-38- KX6B22 COMM 1 XMIT Kfl COMM1 1- 1
i
c VH COMM RAO O IRCA AVC-1101- --PMO-K-CNSUA22 C --RV544~2-
1. THIS WIRING DIAGRAM SHOULD BE USED WITH THE APPLICABLE ELECTR ICAL VHF RADIO XCVR (KY 170 OR KY 195) 7--KR85-9A22 D
PANEL LIGHTS V
~P171-40-- KX14A22-RED
7
D
-4pOZ2_1
SYSTEM WIRING DIAGRAM IN HMI-VOL 1 FOR COMPLETE CIRCUIT IDENTIFICATION.
(FOR AVIONICS INFORMATION OTHER THAN I NTERCONNECTION WIRING INFORMATION P509-A CNS17C22
I AVIONICS +28 VDC BUS
INOTL?I
VHF COMM RADIO (RCA AVC-IIO)-
SSB RCYRIMCITER [SUNAIR RE 12ml
-P500-S- -CNS8A22
W--AS84AL2
E
Hn ~ZB RFCVID(CITER (IVNAIR RE LZOO)
I
~----PPA-N ASB18A22--
E
-RV543A22-C-OM_M2 XMIT KEY
-----CdM~M .203j
F
ON OPTIONAL AVIONICS tOUIPMDIT, RBER TO APPLICABLE OPT EQPT MANUAL. XMIT-COMM 1-COMM 2
2 1
$28 VDC TB502-9 I I I TB6-1-- KX 148 22N (SH I ELD) ------t----l j SWITCH (513)
2. WIRE LEGENDS:
O
L~L1 7. 5A
A VHF RADIO XCVR (KX 170 OR KY 195)
TB502-2
A C_OM_M_1MIC_A_UDIO 41
INTEGRATED INTERPHONE SYSTEM (ICS) CB108 I -RV542A22-
BASIC HELICOPTER ELECTRICAL SYSTEM ICSINAYICCMM B VH RADIOXCVR (KX 110 OR KY 1951 ~i---P171-39-- KX14A22-BLUE- B
TBb COMM 2 MIC AUDIO
OPTIONAL BAS IC I NTERFACE C VHF COMM RADIO (RCA AVC-110) ----CNS14A22 C RV541A22-
PANEL LIGHTS V
3. TERMINAL BLOCK MODULES ARE INTERNALLY BUSED AS FOLLOWS: o)l D SSB RCVRIEXCITER (SUNAIR RE 1200) ~L------PBA-U PSB17A20
E E RV540A22-- X_MIIM_IC_AU_DIO_ _
~_ _ _ _
VHF RADIO XCVR(KX 170 OR KY 195) -P171-21 ----KX15A20N 22--TB502-2 (SMIELD F P509-D CNS14B22
IAA BB CC 01D IAA BIC
BIC DIE
D FI IAA B CIO
CID E FIF IAA C OD EE
BB t FI P509 (SH-IELD)----- RV511A22 1,i
F
0-0 00 0000 0~0 ~O ~O OQ ~O 000 00~000 P509-B CNS9Bn "I 4B22N--TB502-ID (SHIELD TB502-10 I r
TB6- E2 CNS57F22
TB-502-3
4. AT REPLACEMENT, CONTROLS ON NEW UNIT MAY REOUIRE ADJUSTMENT. VOLTAGE CONVERTER (KING KA39) KA39G KX3B20N TB502-28
P509-M --CNSbA22 A
(RBER TO TEXT. VHF RADIO XCVR (RES ISTOR R17) R17 KX782dU TB502-3 D NAV AUDIO VHF COMM RADIO (RCA AVC-110)
---P5M)-G----CNS15A22-- A
2 llA22-- (SHIELD) B
TB502-10C ADF RECEIVER (KING KR 85 -P503-18--CNS63A22-- --P500-J ---CNS39A22- B
ADF RECEIVER (KING KR 85) P851-9 KR85-1022N IN GROUND BUS
5. WIRE END IS OPEN, INSULATED AND SECURED (STOWED). 1-5 -KR85-8An-R C VHF NAV RADIO (RCA AVN-211)- P503-19 -CNS64A22- C AUDIOCOMMON
TRANSPONDER SET(TRbllB-28- P553-P TR611-5A20N 3 ADF AUDIO
6. FOR INTERCONNECTION WIRING INORMATION ON AN OPTIONAL EQUI PMENT NOT -CNS33An D P851-6 ~KR85-8A22-BLUE D
SSB RADIO RCVRIEXCITER (SUNAIR RE 1200)------ Z -ASB82AA22 E
L
SHOWN, REFER TO APPLICABLE OPT EQPT MANUAL. 1 1(4
_ _ _ _ _
(,,,,,,,_ -CNS12A22 E
COMM 2 RCVR AUDIO
-CNS34An F F ~-RV514R22
7. COMMON BUS FOR VHF RAD 10 XCVR (KX 170 OR KY 195) AND VOLTAGE CONVERTER
(KA 39), (REF~ER TO APPLICABLE OPT EOPT MANUAL). I TB502-ll I I TB502-4
6 L~---- P509-K--CNSllB22----I A P509-T---CNS13B22 A

COMM 1 RCVR AUDIO UDIO COMMON
RV511A22--TB6-1 LVJ VHF COMM RADIO (RCA AVC-110)------ --P500-F ----CNSllA22 B
P509 B
CI I I Ic
t28 VDC A ~--CNS17C22--TBS01-2 I I D I I I PHONELO D RV514F22 TB5-1C
I
COMM XMI T KEY dd CNS12B22----TB502-1A I G-- P509- P----CNS16B22-- V CNS56A22 E
I
E
XMIT MIC AUDIO D ~CNS14B22 TB502-~ AIIX RADIO
F F
AUDIO COMMON T B22--T8502-4A
PHONE LO V ~----CN 556A22--- TB502-4E I TB502-12 I TB502-5
-I
PHONE HI U SnA22---TB502-5F
TB106 RESISTORAND DIODE BOARD -TB106-2- -RV51492 PHONE HI A
COMM 2 SI DETONE S S10B22---TB502-6A
COMM 1 SIDETONE R V514P22-TB502-5D SSB RCVRIMCITER (SUNAIR RE 1200) ----P8A-X ---ASB20A22-- B DIO COMMON
S18A22 TB502-6C
NAV AUDIO VHF RADIO XCVR (KX 170 OR KY 195) P171-15 KX20A22 ADF RECEIVER (KING KR 85) ~TB106-3----RV514T22 C
M ---TB502- AUDIO NO. 1(NOTE1)
ADF AUDIO N EPO WARNING UNIT ----P19-C ---B33A22 4 P22----T8502-12B
S33A22 TB502- D
COMM 2 RCVR AUDIO TB106 RES ISTOR AND DIODE BOARD ---TB106-1 RV514o22 PHONEHI 14B22----TB7-3F --~I( B
L S~4A22 TB502-10F E
COMM I RCVR AUDIO K TB502-llA AUDIO NO. 3 (NOTE 1) S22A22 F
S11B22 EPO WARNING UNIT-- ---P19-M ----RV514A22--
AUX AUDIO P 6822 TB502-llE
I I
RIGHT REAR ICS KEY ZE CNS31A22 TB7-8F I I I I i I
LaT REAR ICS KEY bb C--CN S29A22~TB 7 -90 A
S CNS10B22 COMM 2 SI DESTONE
RIGHT REAR MIC HI J ~--C N S55A22 --TB 7 -11D I
I I 1 I B
P5D9-R KX8A22 C
L~i REAR MIC HI COMM 1 SI DESTONE
H ~----CNS15B22--TB7- UHF RADIO XCVR (KX 170 OR KY 195) ~P171-34 KX8AZ2 D
PILOT MIC HI C CNS24A22 TB7-1OB I I I I VHF COMM RADIO (RCA AVC-110)~ ---p5rX)-L~CNS16A22-
I I E CONTINUED
GO-PILOT MIC H I E 532A22~TB7- ON SHEET 2
F I I I
CENTER FRONT ICS KEI a_8 S25A2z--- TB7-8C
JUMPER USED WHEN
CENTER FRONT MIC H1 F~----CN S30A22~ TB7-1OF
I I I I T~7 RCA VHF COMM RADIO i
GO-PILOT ICS KEY Z A22--TB5-1A
L534A--- ----IA IS INSTALLED INSTEAD
r
PILOT ICS KEY Y S20A22~TB5-2B
CF KIM;YHF COMM
.PILOT XMIT KEY
GO-PILOT XMIT KEY
W
X
S23A22 TB5-48
CNS1PAZ2 TB5-2C ii I I I I (NOTES 1, 2)
L5348--
L533D--- ----IC
B
RADICI~
PANEL LIGHTS V
DC GROUND L533C-- D
B CNS9822 TB6-1
L533A-- -I E
F t---1533Bn~TB502-8A
INTEGRATED INTERPHONE
SYSTEM
CARTER CE 500 MT-36 I I I I
ICS AMPLIFIER
(CONTROL UNIT) (NOTE G
47-052-1
Figure 2-1. Int~egrated interphone (ICS) system wiring diagram (sheet 1 of 2)
2-7/2-8
CSP-017 Ol,t Eql,t XI;lllual
TB7-1
J513
A RV5111I.. J547-A
B ~----BLK------------ J513-4
C I-- RV510B22~---- J545-A
TB7-7F GRN
i, I I 1 ~--GRN LO~
AUDIO COMMON TB7-10A RED 1 3 ~-RED
D RVS10H22 J546-A
TB7-3 B~- WHI HI P 110 i Iii I GH T1
2 ~--WHT
E J544-A
1 4 ~--BLK LO I
TB5-1D----RV510C22 ~-------I F
XM I T~ICS
j I I I 1 J544 1 a 654321
A C-- RV514H22---- J547-D
B 5513-2 1 1 II ~------TB71NOTE 5)- RV516~2 I E t-BLU
PHONE HI C I RV514F22 J545-D I r, I I RV508D22 ----I I F C-YEa
D RV514G22 J546- D RV510A22 I A ~-BLK r -----------------LO-~ 1 4
E RV514E22 J544- D 1 1
TB7-3E RVS14~2 D t--fWHT r H I 1 2
I 1
TB502-5E --RV51422~ F I I I I I )-----TB7-OC--- RV539A22-RED~ I B t;dt-RED ~L HI-i 3 n
TB7-7A RV539A22-BLU~I I C ~i=iGRN --------,LO --I I 1
TB7-7
A RV539A22-BLU J544-C
RV531A22
I
COPILOT ICS KEY XMIT- -ICS
B RVS08D22 J544-F
TB5 -1B RV508 C22 C J545 ~5_4_ 3 2 1- 1.
TBS-2A RVS501 D22 D
PILOT ICS KEY E I I I I I l--TB7(NOTE5)- RV506C22--------I I E
F ~----GRN -----------J513-1 1 I 1 r I RV507C22 ----I I F ~YEL
TB7-1G-- RV510B22 I A ~-BLK LO-~ 1 4
TB7-8 I I (E14)-+\YHTIBLK~J I TB7-3C---- RV514F22 I D CC M,HT HI-i 1 2
TB7-1OE~ RV540A22-RED B RED ~cHI CENTER KONT
J545-C 3
CENTER FRONT KEY A RV540A22-BLU
I
TB7-8A-- RV540AZ2-BLU C LGR i10~ I 1
B RV507C22--- J545-F
P509-aa --CNS25A22 C I I I I I I I I RV529A22
I
D
XM I T~-, ICS
RIGHT REAR ICS KEY E RV538A22-BLU ---J546-C
P509-bb CN S31A22 F J546 654321
787-9 ~t TB7(NOTE 5)- Ry525C22 I E

TB7-aD RV526C22 I F t--YEL
A RV537A221BLU --~-J547-C
LDTREAR ICS KEY TB7-ID RV510H22 I A ~-tBLK LO--( 4
B R V527 C22 J547 -F
TB7-3D---- RVS14G22 D WHT HI 2
PS09-ce CNS29A22 C
IB7-1lC RV538A22-RED B RED ~tHI RIGHT REAR
D
3
I I I
TB7-8E RV538AL2 C LO--I I
RV533A22BL"
~GR 1
TB5-1
F
~SJ9-i CNSLlkZ A RV5i)dDZZ --J109-W L
CO-FILC~T ICS KEY RV50dC22 TB7-7C XMIT~----, ICS
TB7-10
TBS02-4D-- RV514F22 C
J547 I": 65432
i i
PS09-C~CN524A22 B
TB7(NOTE 51- RV52dCZ2 -----f I E BLU
II
GO-PILOTIL1IC HI C RV539A22-RED J544-8
TB7-9B RV527 C22 F YEL
TB5-2 P509-E ---CNS32A22 D
CONTINUED
SL-IEET;
T87-7D
PSIJ9-Y
RV5i)ID2Z
CNSLOAZZ
A
B
RV501A22
PILOT ICS KEY
J130-W X P509-F
CENTER FRONT MIC HI
CNS30A22
E
F
RV540A22R ED J545-8
TB7-1A~RV510J22
TB7-3A RV514H22
A
D
BLK
WHT
LO
HI
4
2
TB7-11A---- RV537A22-RED B R HI 3 LET REAR
(SEE _I1EEI CNSl9A2L----( C t---RV516C22
F,R I\iOTE~l D GO-PILOT XMIT KEY
--J109-PJ~MPER (4 PLACES) TB7-ll
TB7-9A RV537A22-BLU----~tl I C ~-GRN I
HEADSET S\NITCH AN D JACK ASSEMBLY

I 1
RV535A22
LEFT REAR MIC HI A RV537A22-RED ---J547-B 1 _14 PLACES)
TB5-3 H~CNS15B22 B
RIGHT REAR MIC HI C I--- RV538A22-RED---J546-B----J (E15 rRV534A22N J130 P1~0
P509-J CN S55A22 D
2ND POS
T
/RV516E22 J544-E TB5-4B RV505B22 P 1 XMIT PILOTS
IST POS
RV506C22 J545-E TB5-2A RV501A22 W 3
NOTE5 t ICS RAD IO-ICS
RV525 C22~ J546-E E5 RV502A22N~ T 2 r.
TB5-4 SWITCH
RV528C22---- J547-E
P509-W---CNS23A22 -----I B RV5i15B22 J130-P RV510F22

C J109 P109
PILOT EM IT KEY
D 2ND POS
TB5-2C RV516C22 1 XMIT GO-PILOTS
1ST POS t
TB5-1A RV508 D22 3 IcS RADIO-ICS
RV524A22N 2 V SWITCH
E7
Fi6ure 2-1. Integrated interphone (ICS) system Wil.ill~ di:l~1.;II11 (511((11 2
1]
T~-,o
CSP-017 Opt Eqpt Manual Se iona
NOTES:
TB502-12 PIO P/O
AUDIO WARNING P509 P509 1. COMPLETE INTERCOM CIRCUITS SHOWN ONLY FOR ONE 5. SOLID TERMINAL BLOCKS WITH MULTI PLE LETTERS INDICATE
TONE NO. 1 (FROM TYPICAL STATION (PILOTS). ALL CONNECTIONS ARE COMMON ON THAT BLOCK.
EPO WARNING
2. SOLID ARROWHEADS 6. FROM
UNIT; NOTE 7\ TB7-ll
RIGHT REAR MIC HI
IND ICATE SIGNAL PATH ONLY.
N1/NR EPO WARNING EOU i PMENT (SECTION 17, HMI-VOL i).
D J INTEGRATED INTERPHONE SYSTEM
MICHI 3. THIS DIAGRAM SHOULD BE USED WITH APPLICABLE 7. THIS CIRCUIT CONNECTION (TB JUMPER WIRE) USED ONLY WITH
TB7-10 LEFT REAR MIC HI CONTROL UNIT
PILOTS I TB7-10 B H AUDIO AVIONICS INTERCONNECTION WIRING DIAGRAM IN RCA VHF COMM (OR COMMINAV) RADIO EPU IPMENT.
J5U AUDIO WARNING
MICROPHON~ 1 CENTER FRONT MIC HI CIRCUITS (CARTER CE 500 HT-3G ICS AMPLIFIER) APPLICABLE OPT EQPT MANUAL FOR REMAIN ING INTERCOM
8. WIRE LEGEND:
HI
3 A
MIC AUDIO HI I F
X plLOTMICHI FROM IW
STATION CIRCUITS.
INTEGRATED INTERPHONE SYSTEM (ICS)
B i 4 REFERhlCE OESIGNRTORS MI\Y NOT BE ON COMWNEEITS. OTHER OPTIONAL EQUIPMENT
TB7-I TBb WPIRNIYG
CENTER FRONT ICS KEY
LO
GRN L RN! F TB5-2 aa UNIT (NOTE 7) BASIC c----)
PILOT ICS KEY (GND) 9. USED WITH INTEGRATED INTERPHONE SYSTEM AND RADIO
Y ICS
WHT/BLK B
TB502-12
I TE 7) RIGHT REAR ICS KEY KEY CONTROL EQU i PMENT.
D A cc
TB5-1 DIODE I 1 I I I I 1 F
COPILOTICSKEY
C---I Z
A CIRCUITS ~8106
LEFT REAR ICS KEY PILOTS E
bb t28VDC
JUO PUO TB5-4 1
XMIT KEY (CONTROL GND) PILOT XMIT KEY XMIT
XMIT
P B
WI
1 RELAY R30
ICS KEY (CONTROL GND)
3~W I
TB502-11 CR10
P500 AUX AUDIO
----I-- -7
L 2 ~3_1 TB502-5
2--T E P TB502-12 AUDIO
+VDC
:vHFRCVR -XMITR RADIQ tVDC tVDC
i
COMM 1 F RADIO-INTERCOM
OUTPUT
COMMON
TB502-6 A STATIONS
PILOTS ICS-RADIO COMM 2 SIDETONE TRAN SFORMER TB502-5 TB502-4
(RCA AVC llOA) S (NOTE 9)
SWITCH (CYCLIC T1 B D AUDIO
B D J544
COMM 1 SIDETONE MIC MIC PHONE COMMON TB7-3
CONTROL STICK) C R PHONE HI LO
L D TB7-10 ICS BLK 4
FROMXMTR SIDETONE COPILOT MIC HI PREAMP AMP AMP D RIR HEADSET (5546-D)
D E R8 A HI
TB502-11 E D WHT
PH(INEHI 2
(X)MM I RCVR AUDIO E F
A K
A LIR HEADSET (J547-D)
AUDIO OUTPUT F C------(B C C/F HEADSET (J545-DI
TB502-10 ICS J513
COMM 2 RCVR AUDIO RELAY
F --IL ~8502-4 HI
B WHT 2
FROM E F TB5-1
ILOT LO COMM LEFT
+28 VDC B BLK 4
RCVR Te502-4 AUDIO COMMON V E C
T XMIT
A PHONE LO
TB6 RELAY 28 VDC D
AUDIOCOMMON I G t-s-I A D
F
MICAUDIO COMMON B A LIR HEADSET (5547-A)
J TB502-1
XMIT C CIF HEADSET (J545-A)
AUDIO F t-( B COMM XMIT KEY (GND) MIC AUDIO
KEY A
COMMON TB5-2 dd X E
C DIODE SHIELD
COPILOTXMITKEY
C X CIRCUITSI I I I I I B ~--1 TB7-1
COMM 2 P500
P503 TB6
SIDETONE
I VHF NAV RADIO +VDC VHF COMM 1 RADIO
I RCVR
TB502-10
R25
SIDETONE
RCVR- XMTR
I (RCAAVN-211A) TB502-1
NAV NAV AUDIO AMP (RCA AVC-I10)
A M COMM 1 X~LIIIT KEY (GND)
D K
RCVR AUDIO
COMM 1 1
I
1
NAV AUDIO 18 B C XMIT KEY
AUDIO COMM 19
R22SIDETONE XMIT MIC AUDIO
TB502 2 2
I
3 COMM 2 XMIT KEY (GND)
E
(GND)
TO XMTR
L-- NAVICOM
CB108 TB501
D F TB502-1E
T8502-2
DC RCVR XMITMIC AUDIO
+28 VDC B H MIC AUDIO
A VOLT +28 VDC AUDIO 4
+28 VDC \5--Y2 5 A
REG INPUT
E
;j ~J
3 CIRCUITS 6 COMM ZXMITMICAUDIO
C
ADFAUDIO TB502-2C
TB6 N
COMM 1-XMIT-COMM 2
DC GND
1)~ B SWITCH (S13)
47-053
Figure 2-2. Integrated interphone (ICS) system control circuits
2-11/2-12
o_ )~COMM 1ADJUSTMENT
P ~T CONTROL (NOTE 3)
I
,8 sc~-- COMM 2 ADJUSTMENT
I CONTROL (NOTE 3)
t;ul~----- I CS A DJ U STMENT
CONTROL (NOTE 2)
(NOTE 1) SCREWS, WASHERS

(4 PLACES)
INSTRUMENT
CONSOLE
STRUCTURE
LOOKING INBOARD
TB501
ooi~il NOTE 4)
ol
oj
O
CE 500 HT-3G ICS AMPLIFIER
04
(CONTROL UNIT)
O
I ~TB502
I 1
~1
CONSOLE
HORIZONTAL
LOOKING AFT
SUPPORT
O
Q
NOTES:
i. STRUCTURAL ELECTRICAL BOND TO CASE OF UNIT IS REQUIRED (SECTION 19,

HMI-VOL i).
2. AT REPLACEMENT OF CONTROL UNIT, ADJUSTMENT OF INTERPHONE MICROPHONE

AUDIO LEVEL IS REPUIRED. (REFER TO TEXT.
3. AT REPLACEMENT OF CONTROL UNIT, ADJUSTMENT OF SIDTONE AUDIO LEVEL

FOR ASSOCIATED VHF COMM RADIO IS REQU IRED. (REFER TO TEXT.
4. PART OF HELICOPTER BASIC ELECTRICAL SYSTEM (SECTION 19, HMI-VOL 1). 47-051
Figure 2-3. Carter CE 500 HT-3G ICS amplifier (controlunit) installation
2-13
Table 2-2. Input and output test signals for interphone control unit
Input Output
Signal Enable Ground at Signal

Check (Vac at 1000 Hz, 5509 Pin No. 5509 Pin No. (Vac at 1000 Hz, J509 Pin No.
No. rms) and Letter or Letter rms) or Letter
+0.2
1 8.00 K to T None 6. 0 to 9.0 U to V
-0.0
+0.2
2 8. 00 L to T None 6. 0 to 9.0 U to V
-0.0
+0.2
3 8. 00 M to T None 6. 0 to 9.0 U to V
-0.0
+0.2
4 8. 00 N to T None 6.0 to 9.0 U to V
-0.0
+0.2
5 8. 00 P to T None 6. 0 to 9.0 U to V
-0.0
+0.2
6 1. 8 R to T None 6.0 rtO. 5 U to V
-0.0
+0.2
7 1. 8 S to T None 6.0~0. 5 U to V
-0.0
+0.010
8 0. 100 C to T W 0. 100 ~0.010 D to T
-0.000
+0.010
9 0. 100 E to T X 0. 100 ~0.010 D to T
-0.000
+0.010
10 0. 100 F to T aa 6.0 rtO. 5 U to V
-0.000
+0.010
11 0. 100 H to T bb 6.0~0. 5 U to V
-0.000
+0.010
12 0. 100 J to T cc 6.0 ~O. 5 U to V
-0.000
+0.010
13 0. 100 C to T Y 6.0 rtO. 5 U to V
-0.000
+0.010
14 0. 100 E to T Z 6. 0 ~-0. 5 U to V
-0.000
Diode conti-
15 Use ohmmeter W to dd None None
nuity check
Diode conti-
16 Use ohmmeter X to dd None None
nuity check
NOTES: i. For checks No. 5 through It: Input signals are to be applied through a series connected
10 mfd capacitor. With input signal applied, enable ground (electrical connection
between pin B of 5509 to connector pin listed) is to be applied to obtain output si~al.
Pin T is audio common connection.
2. For diode continuity checks No. S and T: ~XJith ohmnleter positive lead connected to pin
DD and negative lead to other pin listed, ohmmeter should indicate low forward resist-
ance. With ohmmctcr lends reversed, ohmmeter should indicate high back resistance.
3. If necessary, adjust controls on the unit to obtain the listed outputs. (Refer to para 2-7
for informxtion on ;1~ I~rnal circuits and external adjustable controls.
2-14
Mawal Section 2
CSP-017 Opt
NOTES:
1. EXTERNAL ADJUSTMENT CONTROL (R8. R2 AND Rn). 5. UNLESS OTHERWISE INDICATED, CAPACITANCE VALUES
128VDC
-ZBVDCGROUND
I
A
B L~
I
CR1
R1
300
DC VOLTAGE
REGULATOR Q1
I 2. ARROWHEAD
SIGNAL FLOW PATH.
INDICATES AUDIO OR CONTROL
3. XMIT AND ICS KEY CONTROL INPUTS ARE -28 VDC

IN MICROFARADS AND RESISTANCE VALUES IN OHMS.
6. UNLESS OTHERWISE INDIGATED, ALL DIODES ARE IN4002.
7. ABBREV IATIONS USED TO IN Di GATE INTERCOM STATI ON

C2
100 ~f
v~Tjtl GROUNDS. LOCATIONS ARE AS FOLLOWS:
CIF CENTERFRONT
R2 +12 VDC 4. REFERENCE DESIGNATORS ARE FOR REFERENCE ONLY
LIR LEFT REAR
K2-A AND MAY NOT BE ON COMPONENTS.
C7 RiR RIGHT REAR
1 910 CR3 200, 1W
C3
~Faa VR2
XMITMIC AUDIO
COPILOT MIC HI
D
E
K3-A
1
R4
910
4.7
R29
R30 .i
ilFMICHI F
R5
4.7C20 R8
2. SK C8
C11 R9
3.3K
1
910
C21 910
IcS 1 4.7 ~Y I
R31 MICROPHONE AUDIO
4.7
(NOTE II R 11 OUTPUT
R6 PREAMPLIFIER 42 Clb
LIKMICHI H 4 TRANSFORMER
910 T1
C22 05
C13 5 C17 4n loOn
KI-A B HA 7 U PHONE HI
R33 6
4.7 MICROPHONE 0002
C27 10 8 110
100K 1
cs~Y4
R7 9 ,Iir
AMPLIFIER 03 C18 ~V PHONE LO
R!RMICHI
C14 1 .1
910
C23 R32 ool~ PART OF
C15 R12 :509
270
4.7 R34 4.7 470
R14
4.7K INTERPHONE
COMM 1 RCVR K
470 AUDIO
R1S
COMRn 2 OIDUARVCR L
AMPLIFIER
470 R13
AUDIO Rib
22
NAV AUDIO i Iv\
470 R17
ADF AUDIO N
470 R20
R18 X
AUX AUDIO P
4.7K ICS RELAY
470 c28 VDC
K1
~:9 R36
C26 R42
22K R27
CR7
R38
R35 C T ~56(3 4.7 R28
C31
3.2K
comn11510~0NE R
1.51:
ICDMMII 1 Y Z KZ-B
(NOTE 1I R23 SIDETONE
C29 R22 IO
AMPLIFIER 04 PILOTS COPILOTS
.00~ 2.5K 4;7K
R39 1. O CRS X~IT K3-B
CR6 Y
470) R37 o
680 RELAY RELAY I
R40 330
K2 K3
2
COhlhl 2SIDETONE 5
tH(
ICOMMZJ
(NOTE 1I R26
R24, C30 R25
osO CR13 CR14
2 5K R41 4. 7K
AUDIOCOMRION Tr CR9 CR1B CR1I CR1Z
1 i I I 1 ~680 (4701
bb cc
PARTOF
W dd X Y aa
JS09
PILOT COMM CO PI LOT PILOT COPILOT C/F i/R R/R
XMIT XMIT ICS ICS ICS ICS ICS
XMIT
KEY kEY KEY KEY KEr KEY
KFy #EY
2-4. Carter CE 500 HT-JG ICS adapter (controI Unit) schematicl

Figare
2-15/2-16
R~DIO-ICS switch on the pilots

cyclic stick at the assembly provides for selection between vhf
i
position is used to select the mode of

operation. COMM 1 and/or COMM 2 radio equipment (if
Voice transmission over the interphone from any installed). The assembly consists of a DPDT
intercom station except the pilots station is toggle switch, located on the lower switch and
selected by setting the switch/jack at that station circuit breakerpanel on the front of the instru-
to ICS. Positioning the RA~IO-ICS switch to ICS ment console, and
attaching wire assemblies.
on the pilots cyclic stick selects voice transmis- The switch controls application of transmit keying
sion over the interphone. Setting the switch/jack i microphone audio signals to either vhf COMM 1
to ICS at the copilots station (369MD) selects or vhf COMM 2 radio equipment.
voice interphone transmission. The XMIT posi-

tion of the RADIO-lCS switch on the pilots cyclic
stick keys the transmitter of the vhf receiver- 2-14. ADJUSTMENT OF INTERCOM MICRO-
transmitter. Setting the switch/jack to XMIT at PHONE ~I1UDIO
the copilots station (369MD) selects vhf radio PHONESYSTE
transmission. The middle (released)
switch
position selects vhf receiver audio and is the NOTE: The ICS control RS adjusts level of
listening position for interphone and monitoring interphone microphone audio signals before
the vhf COMM, vhf NAV, ADF and DME receivers. amplification by microphone amplifier in the
Switch/jack assemblies are removed or installed unit to control headset phone volume during
by disconnecting the unit at the bulkhead headset interphone operation. (The ICS control does
connector. Figure 2-1 provides a schematic not affect the level of received audio signals
diagram for the headset switch/jack assembly. from any installed radio equipment.) Adjust-
ments are as follows:
2-11. HEADSET-MICROPHON%S. Either oneof
two s (carbon a. Gain control, located on right
access to ICS
or dynamic microphone) is used with the vhf com- end of Carter CE 500 HT-3G ICS amplifier (con-
munications installation, if installed. Each type trolunit), by removing instrument panels right
contains two earphones attached to a coiled re- side fairing (Section 17, HMI Vol 1).
tractable cord with a headset plug. The headset b. Connect headset-microphones at all radio/
plug contains a standard U-174/U phone plug to intercom stations.
mate with the headset jack of a headset switch and c. Energize interphone system with NAV/COM
jack assembly (para 2-10). A noise canceling circuit breaker.
microphone is mounted on the end of an adjustable d. Adjust ICS control RE until desired headset
wire boom on the headset. Each of the two ear- earphone volume is obtained in headsets while
phones on the headset is encircled with a padded operating the intercom system and speaking into
headband. microphone.
2-12. PILOTSHEADSETJACK. Theinstalled NOTE: If sufficient intercom microphone

pilotsheadset jack (fig. Z--1) a phone contains audio volume cannot be obtained in headset
jack that mates with a standard U-174/U inter- earphones by adjustment of ICS control,
phone plug for connection of the pilots headset, refer to troubleshooting procedures
(table 2-1).
2-13. COI1IM 1-XMIT-COMM 2 RADIO SELEC-
TOR e. Reinstall right side fairing on instrument:
COMM 1-XMIT-COMM 2 radio selector switch panel (Section 17, HMI Vol 1).
TB502-1
COMM XMIT KEY RV545A22 CONTACT TIP (TYPICAL) (NOTE 1)
i-~il
2
1 COMM 1 XMIT KEY RV544A22 cj
NOTES:
COMM 2 XMIT KEY RV543A22
COMM 1- XMIT COMM 2 ~P-Ej i. ONE MPCM20M-H2 CONTACT TIP
SWITCH (S13) COMM 1 MIC AUDIO RV54ZA22
~o REQUIRED ON END OF EACH WIRE.
5 COMM 2 MIC AUDIO RV541AZZ22A145VR,I
6~ CI 2. ALL WIRES AWG 22, MIL-W-5086. TYPE II
XMIT MIC AUDIO f~ I

I APPROXIMATELY 36. 00 0.50 IN. LONG.
TB6 L~ E_1
CNS57F22 T8502-2
41-054
Figure 2-5. COMM 1-COMM 2 XMIT switch assembly schematic
2-17
Section 2 Opt Eqpt Manual CSP-O11
2-15. ADJUSTMENT OF VHF COMM NOTE: If sufficient sidetone audio volume

RECEIVER- TRANSMITTER SIDETONE LEVEL cannot be obtained in headset earphones by
(INTEGRATED INTERPHONE SYSTEM). adjustment of COMM 1 and COMM 2 controls,
refer to troubleshooting procedures
NOTE: COMM 1 and COMM 2 sidetone (table 2-1).
controls R22 and R25 adjust level of side-
tone audio from vhf COMM radio No. I and f. Reinstall the instrument panel right side
COMM 2 (respectively) that is applied to (Section 17, HMI- Vol 1).
headset earphones during vhf COMM radio
transmission. (COMM 1 and COMM 2 side- 2-16. ADJUSTMENT OF INTERCOM PHONE
tone controls do not affect level of microphone AUDIO LEVEL INTEGRATED INTERPHONE
audio or of any received audio signals from SYSTEM (CqNTROL UNIT).
any installed radio equipment.) a. For access to control unit by removing
instrument panel side fairings (Section 17,
a. Gain access to COMM 1 or COMM 2 control HMI- Vol I).
as applicable, located on right end of the control _b. Connect a headset-microphone at any
unit, by removing instrument panel right side radio/intercom station.
fairing (Section 17, HMI- Vol 1). c. Energize integrated interphone system with
b. Connect headset-microphones at all NAV/COM circuit breaker.
ra~io/intercom stations, d. Check that earphone audio level is correct-
c. Energize intercom system and vhf COMM ly adjusted for all other radio communication
radio(s) with NAV/COM circuit breaker. equipment that may be installed (para 2-4).
d.
While transmitting with vhf COMM radio e. Recheck and readjust vhf COMM receiver-
No. 1 or 2, adjust COMM 1 or COMM 2 control transmitter sidetonelevelas necessary(para 2- 5).
as applicable for desired sidetone audio volume f. Reinstall instrument panel side fairings
in headset earphones. (Section 17, HMI- Vol 1).
2-18
CSP
019
Illustrcrted Ports List

and
FOR
AUTOMATIC DIRECTION FINDER (KR 86)

Part No. 369H90056 Basic and
369B90056-501
E) Hushes Helicopters
COD671110 Issu.ed 1 March 1977

NI FG,
INTRO
RECORD O~ REVISIONS
CSP-019
MFG REV

CSP-O~O Opt EQpt Manual Table of Contents
AUTOMATIC DIRECTIVE FINDER
TABLE OF CONTENTS
Section Page
FOREWORD F-r

of this Manual F-l
and Revisions F-l
1-I. Scope and Contents...... 1-1

List 1-1
1-3. Illustrations
2 MAINTENANCE INSTRUCT~ONS.. 2-1
2-1. General Information..... 2-1
Section Page
(CONT)
2-2. Description of KR 86
Receiver 2-1
2-3. Description of Wire
Harness Assembly 2-1
2-5. Description of ADF
Sense Antenna......... 2-1
2-8. Operational Check...... 2-3
2-9. Alignment 2-3
2-11. Replacement of KR 86
ADF Receiver......... 2-3
2-12. Replacement of KA 42
2-14. Repair 2-5
FOREWORD
groupings, and major components that are
contains instructions for maintenance of the these are presented in sequence as defined in
KR 86 automatic direction finder (ADF) installa- Section 1, HMI Vol i.
tion. This manual also contains parts lists for
procuring replacement parts for the automatic F-5. USE OF THIS MANUAL. This manual is
direction finder installation. for by operators of the Model 369D helicopter
use
equipped with ER 86 automatic direction finder.

F-2. APPLICABILITY. The ]KR86 automatic Although this manual is a separate publication, it
direction finder is applicable for use on any should be kept with HMI Vol 1, HMI Vol 2,
Hughes 500D (Model 369D) helicopter. 369D IPC and other handbooks listed in Section 1,
HMI Vol 1 that form the primary information file
F-3. COMPATIBILITY OF COMBINED for the helicopter.
OPTIONAL EQUIPMENT. For compatibility
may not be used in combination at the same time, made to applicable portions of HMI Vol 1 and
refer to Section 21, HMI Vol 1. 369D IPC as required to accomplish instructions
contained herein.
as outlined in the Table of Contents. Each sec- Changes and revisions to contents of this manual
to provide comprehensive made as defined in Section 1, HMI Vol 1.
tion is organized are
F-1/F-2
SECTION 1
1-1. SCOPE AND CONTENTS. This illustrated 1-2. GROUPASSEMBLYPARTS LIST. The
parts list provides, by meansof text (parts lists) parts lists furnish information for procuring
and companion illustrations, a complete parts replacement parts for the automatic direction
definition of the 369H90056 Automatic Direction finder installation and shall not be used for any
Finder (I(R 86) installation, manufactured by other purpose.
NOTE: The illustrated parts list is organized is provided for the group assembly parts list. The
and presented in the same manner as the 369D illustration is exploded to the extent necessary to
Series Illustrated Parts List(369D-IPC). (For show parts relationship for the complete automatic
information on use, refer to the 369D IPC. direction finder installation.
1-1
j(
O
3
1
3
20 o
22 26
19
17 1
r------,~i
o ti~23
7
B ei
I J~
/i!
1
-i; i
8::
II i
47-lU5
Figure 1-1. KR 86 automatic direction finder
1-2
UNITS
FIG.
DESCRIPTION PER
INDEX PART
ASSY
NO. NO.
1-1- 369B90056 I(R 86 AUTOMATIC DIRECTION FINDER SYSTEM

MSTL EQPT 1
369890056-501 KR 86 AUTOMATIC DIRECTION FINDER SYSTEM

PROVISIONS I 1
-1 2TC13-2 I CIRCUIT BREAKER I 1
-2 369H6423-505 HOOD 1
3691190056-21 1 HARNESSASSY .............i...........; I 1
KR 86 AUTOMATIC DIRECTION FINDER SYSTEM EQPT

1
(NHA 369H90056)
369B90056-31 1 MISCELLANEOUS PARTS 1
-3 200-0523-01 1 RACK CABLE PLATE ASSY (NHA 369H90056-21) 1
-4 MS21042-08 NUT (NHA 369B90056 and 369B90056-501) 2

-5 AN960PD8L I WASHER (NHA 369B90056 and 369B90056-501) 2
-6 NAS623-2-1 I SCREW ~HA 369B90056 and 369B90056-501) 6
-7 050-1308-03 KR 86 AUTOMATIC DIRECTION FINDER RECEIVER

86) 1
(NHA KR
-8 MS20426AD3 I.. RIVET 8
-9 MS2 1076- 108 1.. NUTPLATE 4

-10 369B90056-3 1.. PLATE 1
-11 MS21042-08 NUT ~NHA 369B90056 and 369H90056-501) I 1

AN960PD8 L WASHER (NHA 369B90056 and 369B90056-501) 2
-12
-13 MS51957-43 SCREW (NHA 369B90056 and 369B90056-501) 2
1 ANGLE (NHA 369B90056 and 369B90056-501) 2

-14 369B90056-5
-15 089-5899-03 SCREW (NHA 369B90056-31) 3
-16 047-2686-01 SHIELD (NHA 369B90056-31). 1
-17 MS2 503 6- 102 LUG (NHA 369B90056-21) 4
-18 MPCM22M-HI HYTIP (NHA 369B90056-21) 3

-19 D121 SLEEVE (NHA369H90056-21) 6
-20 03-1046-08 CONNECTOR (P101) (NHA 369H90056-21) 1

-21 200-0447-00 SENSE CABLE ASSY (NHA KR 86) 1
-22 200-0446-00 LOOP CABLE ASSY (NHA 369B90056-31) 1
-23 NAS1351C4-20 SCREW (NHA 369B90056 and 369B90056-501) 2
AN960C10 WASHER (NHA 369H90056 and 369B90056-501) 2

-24
071-1006-11 KA 42 ANTENNA (NHA KR 86) 1
-25
MS17821-1-9 TIE STRAP (NHA 369B90056-21) AR
-26
1-3/1-4
SECTION 2
2-1. GENERAL INFORMATION. The KR 86 from which the signal is received. The HDG/
homes on se- TEST control is used to manually position the
lected ground radio stations to provide accurate heading card in the face of the indicator. The
bearing information for helicopter navigation. rack cable plate assembly (3, fig. 1-1) contains
It consists of a KW. 86 receiver with integral vhf a voltage converter which converts the +28 vdc
omnirange (VOR) indicator, KA 42 loop antenna, supplied to the receiver to +13.75 vdc at 0.5 am-
wire harness assembly which includes the loop pere, maximum. For additional description and
antenna cable and sense antenna cable, and th~ory of operation, refer to the manufacturers
attaching hardware. The sense all~enna cable publication (table 2-12, HMI Vol 1).
connects to the 369B90146-503 (ASP-3-BL) whip
antenna which is already installed in the heli- 2-3. DESCRIPTION OF WIRE KARNESS
copter. The KR 86 receiver consists of the ASSEMBLY. The 369B90056-21 wire harness
enclosed receiver unit and a rack cable plate assembly consists of a loop antenna cable, sense
assembly which mounts on the rear of the unit. antenna cable, five interconnecting wires, two
The ADF system is powered by +28 vdc from the connectors, miscellaneous parts, and the rack
helicopter main bus, supplied through the 2- cable plate assembly. The wiring diagram for
ampere ADF circuit breaker (CB107) (1, fig. 1-1). the wire harness assembly is shown in figure 2-1.
on the instrument panel. This manual provides The receiver ends of the cables and wires are
maintenance instructions for the ADF system, connected to connector P101 which is part of rack
For maintenance information pertaining to the cable plate assembly (3, fig. 1-1). The wire
KR 86 receiver, refer to the manufacturers harness assembly interconnects the ADF receiver
publication (table 2-12, HMI Vol 1). loop antenna, sense antenna, light dimming circuit,
and ICS audio circuits.
NOTE: An integrated interphone communica-
tiosystem (ICS) must be installed in the NOTE: VBrire connections at connector
helicopter for with the ADF installation.
use P104 must be as shown in figure 2-1
The ICS audio equipment (headset, switch and for proper phasing of loop antenna input
jack assembly and control unit) are required signals.
for reception of ADF voice and code signals.
The electrical interface of the ADF and ICS 2-4. DESCRIPTION OF KA 42 ADF LOOP
is shown in figure 2-1, and the ICS electrical
circuitry is described in the ICS Opt Eqpt fig. 1-I) cconsists of two windings wound at right
Manual (table 21-1, HMI Vol i). angles. The windings are symmetrical with
respect to ground to prevent unwanted pickup.
2-2. DESCRIPTION OF KR 86 RECEIVER. The The magnet field of the radio signal induces a
KR 8 ned voltage in the loop antenna. The relative direction
solid state receiver which operates within the of the signal source determines the amplitude of
200 kHz-to-1750 kHz frequency range. The the voltage induced in each antenna winding.
receiver is flush mounted in the helicopter in- These voltages are used in the ADF indicator to
strument panel. Three
rotary switches
on the position the heading pointer to indicate the angle
receiver front panel are used to select the operat which the radio signal is entering the loop
ating frequency tin 1 kHz increments) and the antenna. The loop antenna is mounted on the
selected frequency is shown on a four-digit dis- underside of the fuselage below the pilots com-
play. The TEST/ADF two-position rotary partment. The ADF loop antenna is connected
switch is used to select the test of ADF mode of to the ADF receiver via the 200-0446-00 loop
operation. The OFF/VOL rotary switch is used antenna cable.
to turn the ADF on, and to adjust the ADF audio
to a comfortable level. The receiver supplies 2-5. DESCRIPTION OF ADF SENSE ANTENNA.
signals to the ADF indicator, flush mounted on The ADF sense antenna receives incoming radio
the front panel of the receiver, to position a signals which are used to produce an audio output.
pointer to indicate the direction of the station Also, the sense antenna input is added to the loop
2-1
Secgion 2. Eqpt CS~L)-019
P101.
3~9H901146-403: SENSE GABLE ANTENNA (REF)
SENSE AN;TENFJA
7
liN PWT
SENSE GIFILE
P104;
UC- C6 I SLEE~E
15 8
I: I
ii: El: I I: I
I II Ii I 3
14 VWHT
LOOP ANTENNA
I:N PUT
17
I/ JU~PEA: a2GA
BLK
~_5
6
I
Ii I PI:
16 RED 1
#A 42
2
LOOP ANTENNA
18 ii F7 LOOe; GABLE
SLEEVE 7 BOTTOM MOUNTED)
JUMPER ZaGA 2 RE90:
3 1/ 3RE$t IE GABLE CCWM;B IREF);
SLEEVE D1
12: FB502-10
P N-
h
~6-8;Pi22---- RED C
liIO I I:
I MPCM22M-HI- PIN-
I:I
AUo[O GOMMON 11 ,I:rew2-s
JUMPER; 2XA
AC POWER GROU[UD- ii 1 2 1 TB6
GROUNO Ii 6
I KWlf
P11S25036-102 LUG
68107
/f\ 2
FROM MELI:COPWR +28 VDC 80-S O O--i
2A
ORANGE ~9;a5036-1QtUG
TE~1IIVAI-SOPDER TB501
tERMI-lx~Cie
8501
+13i75uOC INPU~ 1; 2. C--~

~01
0501 FliPCFII22~-HI PIN;
+12;5 VDC:
86-9A.22
tN:STRUMENT LIG~ I: 5
POWER IN:PUT C 1;1 TI;E STRAP
RUBCER GROM~R IREFT TBf,O2-8
KR BIADP RECEIWER I TOCIGI-1T DIMMER
Clti PLATE ASSW\j~BEY

47-108
Fi;gc~re 2-1;. 86 arrf~atis: eommunicaition

CB~
2 -2
CSP-01S Opt Eqpt Manual Section 2
antenna input to obtain pointing modulation. The of each station to which the receiver is tuned is
ADF sense modified Antenna Special-
antenna is a intelligible.
ists Products ASP-3-BL whip antenna. It is
mounted fore-and-aft on the ADF sense/vhf nav Facility Range
antenna bracket at the center underside of the
fuselage structure. A nut and washer secure the Compass Locators 15 Nautical miles
antetma base to an aluminum plate and phenolic Transmitters 100-200 watts 50 Nautical miles
insulator on the forward side of the antenna Transmitters 200-400 watts 60 Nautical miles
Transmitters over 400 watts 75 Nautical miles
bracket, with the antenna rod element extending
aft through a grommet in the aft side of the an-
tenna bracket. The grommet, phenolic insulator c. Position the helicopter on a compass rose.
and three nylon flanged washers electrically iso- Using a strong station in the 200 kHz to 415 kHz
late the antenna element from the metal antenna band, obtain ADF bearings for increments of
bracket. The ADF sense antenna cable, a part 15 degrees beginning with the helicopter on a
of the 3691190056-21 wire harness assembly, 0 degree heading. Make quadrantal error correc-
connects to the antenna base at the forward side tions, if necessary. The combined error should
of the antenna bracket. When the helicopter is not exceed 15 percent.
also equipped with a vhf navigation antenna
2-9. ALIGNMENT. Refertothe manufacturers
installation, a vhf navigation anten~a is secured
to the underside of the antenna bracket. HMI Vol 1) for instruc-
tion for aligning the ADF system.
2-6. REFERENCE DATA. Informationonheli-
copter components that interface with the ADF 2-10. INSPECTION. Inspect components of the
Vol 1 and 369D IPC. For ADF system in accordance with FAA AC 43.13-1A
system is in HMI
information on optional avionics equip-
associated and standard avionics maintenance practices, and
ment used with the ICS system, refer to the the following:
applicable Opt Eqpt Manual for that specific a. Inspect all components for obvious physical
equipment (Section 21, HMI Vol 1). damage, corrosion and evidence of electrical
overheating.
2-7. T1ROUBLESHOOTING. If the ADF system b. Inspect the ADF receiver for loose or miss-
does notoperate properly during operational ingcontrol knobs, damaged or obscured markings,
check or normaluse, refer to table 2-1 for aid and loose or damaged connector.
in locating the probable trouble and for corrective c. Inspect the wire harness assembly for cuts
action. Refer to the ADF wiring diagram and other damage, loose connectors or connecting
(fig. 2-1) for aid in troubleshooting, If trouble- hardware, and frayed insulation.
shooting indicates that the trouble is in the ADF
indicator or the ADF receiver, refer to the manu- 2-11. REPLACEMENT OF KR 86 ADF
facturers publication (table 2-2, HMI Vol 1) RECEIVER.
for unit troubleshooting and corrective action, a. Check that all electrical. power is OFF.
b. Remove instrument panel side fairings
NOTE: ADF audio is reproduced by compo- (Section 17, HMI Vol i).
Remove hardware that attaches hood (2,
nents of the integrated interphone communi- c.
cation system (ICS) which, in itself, may be fig. 1-1) and remove hood.
the source of ADF audio trouble. When ADF d. Remove rack cable plate assembly (3) being
audio malfunction is encountered, refer to careful to avoid damaging connector.
Remove nuts (4), washers (5), and screws
the ICS Opt Eqpt Manual (Section 21, HMI e.
Vol 1) for troubleshooting procedures for (6), then remove ADF receiver (7).
that portion of ADF audio circuitry. f. Do not: remove plate (10) unless damaged.
g. Do not remove angles (14) unless damaged.
2-8. OPERATIONAL CHECK. The following h. Install the replacement receiver in reverse
capability of the order of removal.
ADF system to function properly. The procedure
should be performed anytime a malfunction is 2-12.REPLACEMENT OF KA 42 ADF LOOP
ANTENNA.
suspected, and prior to normal use after repair.
~PJith other avionics systems operating, a. Gain access to the pilots underfloor com-
a.
pa;-~ment (Section 2, HMI Vol 1).
verify that ADF system operation is not affected
by emission interference from other systems nor
b. Remove loop antenna terminal box attaching
affects operation of other systems. parts and disconnect loop antenna cable.
b. Using distant stations which are known to c. Remove screws (23, fig. 1-1) and remove
provide approximately the same signal conditions loop antenna (25). Retain spacer washers and
which would be experienced at the distances shown rubber gasket for reconnection of cable terminal
below, verify that the tone audio identification box.
2-3
Seeti~ 2 Opt Eqpt Manual CSP-010
Table 2-1. Troubes~iooting
Pr~bable Trouble Corrective Action
in either AD:F: circuit breaker Set circuit breaker

~F or BFe~ mode (1, fig. 1-1): not ON. to ON.
and
inoperative. No; d-c power on Refer to Section 19,
helicopter n~ain bus. HMI Vol i.
Disconnected or Connect or repair

defective wire harness: wire harness
asse~ly. assembly,
Inso;rreet: ~eraCing Replace defective tenet:
voltage due to faulty diode CR502 or transistor
voltage Q501, as rec~uired.
~F circuit breaker Overload or short Repair or replace

trips. circuit in AD:F receiver. ADF receiver.
Overload o:r short cire~k Repair or replace ADF

in wire ~ntess assembly. wire harness assembly.
EZrraneous bearing indi- AD~P systen out of Align ADF system

e~oa, au~o;OK. (para 2-9).
Defective ADF indicator. Repair or replace ADF

indicator
Defective or damaged Repair or replace AD-F

AeE=rF loop; antenna. loop ~enna.
Disconnected or defective Connect or repair loop

loop antenna c~e. antenna cable.
No ADB ~F system of Align ADF system:

~o, bearing out
indication Oil.. alignment. (para 2-9).
Defective AD;F receiver. Repair or replace ADF

receiver.
Defective ~F sease ~enn;a Repair or replace sense
cable. antenna ADF cable.
Mo AD-F. ~cr,, bearing ~F receiver. Repair or replace ~F

receive.
indication incorrect,
~eT
a.-L~
CSP-019 Manual Section 2
Opt Eqpt
d. Install replacement loop antenna in reverse 2-14. REPAIR. Refer to Section 19 of HMI
order of removal. Check that the arrow on the Vol 1 for electrical repair Replace
instructions.
antenna is pointing to the forward end of the heli- damaged cable clips attaching hard-
and other
copter, and that the antenna cable wiring is con- ware with new parts. When a malfunction occurs
nected for proper phasing. Refer to the wiring in the ADF receiver, replace parts found to be
diagram (fig. 2-1) and the manufacturers publi- defective by the troubleshooting procedures pro-
cation (table 2-2, HMI Vol i). vided in the manufacturers publication (table 2-2,
HMI Vol i). Align the ADF system, if neces-
2-13. ADJUSTMENT. If the ADF indicator has sary, in accordance with the manufacturers
a slighterror inpointer position, adjust the publication.
position of the goniometer shield to compensate
for the error in accordance with the instructions
in the manufacturers publication (table 2-2, 2-15. WIRING DIAGRAM. See figure 2-1 for
HMI Vol 1). the ADF system interconnection wiring diagram.
2-s/z-s
CSP
020

and
FOR
RADIO INSTALLATION CASE-125/60)
Part No..369B90144-501,
3691-190144-503 and 3691190144-505
Hughes
COD671110 Issued 1 March 1977

IVI FG I
INTRO
RECORD OF REVISIONS
AP~ CSP-020
MFG REV

RADIO INSTALLATION
TABLE OF CONTENTS
Section Page
I~DREWORD F-l

of this Manual F-l
F-S. Use of this Manual F-l
F-8. RelatedPubllcations F-l
Revisions F-l
1-1. Scope and Contents....... 1-1

1-2. Group AssemblyParts
Ust 1-1
2-1. CeneralInformation 2-1

2-2. Description RE-1200/600
of
Receiver/Exciter .......~2-1
2-3. Description of PA-~O1OB
Power Amplifier/Power
Supply 2-1
RADIO fNSfALLATION
TABLE OF CONTENTS
Section Page
2 MAINTENANCE INSTRUCT1ONS
(CONT)
2-4. Description oiAC31-l

Antenna 2-1
2-5. Description of AC31-2
Control Head.......... 2-2
2-6. Description of AC31-3
ASW Sensor 2-2
2-9. OperationalCheck 2-3
i-10.Alignment 2-3
2-12. Replacement of AC3 1-2
Control Head.......... 2-3
2-13. Replacement of ASB-125/60
Receiver/Exciter 2-3
2-14. Replacement of ASB-125/60
Power Ampllffer/Power
Supply 2-3
2-15. Replacement of AC31-3
SWR Sensor........... 2-3
2-16. Replacement of AC31-1
Antenna 2-5
2-18. Repair 2-5
2-19. Wiring Wagram........ 2-5
FOREWOR D
contains instructions for maintenance of the these are presented in sequence as defined in
ASB-125/60 radio installation. This manual also Section i, HMI Vol i.
contains parts lists for procuring replacement
parts for the radio installation. F-5. USE OF THIS MANUAL. This manual is
for by operators of the Model 369D helicopter
use
F-2. APPLICABILITY. The ASB-125/60 radio equipped with ASB-125/60 radio. Although this
isapplicable for use on any Hughes 500D (Model manual is a separate publication, it should be
369D) helicopter, kept with HMI Vol 1, HMI Vol 2, 369D IPC
and other handbooks listed in Section 1, HMI
F-3. COMPATIBILITY OF COMBINED Vol 1 that form the primary information file for
OP the helicopter.
refer to Section 21, HMI Vol 1.
3691) IPC as required to accomplish instructions
contained herein.
as outlined in the Table of Contents. Each sec- Changes and revisions to contents of this m
made as defined in Section i, HMI Vol 1.
tion is organized to provide comprehensive are
F-1/F-2
CSP-ozo Opt Eqpt Manual Section 1
SECTION 1
1-1. SCOPE AND CONTENTS. This illustrated 1-2. CROUPASSEMBLYPARTS LIST. The
parts listprovides, means of text (parts lists) parts lists furnish information for procuring
and companion illustrations, acomplete parts replacement: parts for the ASB-125/60 radio;
definition of the 3691190144 Radio (ASB-125/60) installation and shall not be used for any
installation, manufactured by Hughes Helicopters, other purpose.
Culver City, Cs~lifornia.
NOTE: The illustrated partslist is organiaed is forthe group assembly parts list. The
and presented in the the 369D
same manner as illustration is exploded to the extent necessary to
Series Illustrated Parts List(369D -IPC). (For show parts relationship for the complete
information on use, refer to the 369D-IPC. ASB-125/60 radio installation.
1-1
11 ---II
il/r;4j "ia~
21 I/Ii
ik:
ii
;J~71,
OY
-i ;ii3~3/ I
2
Is
12 i!
f I~
i
11I
7
a
4
i
13
I jt: iC
I~
ii
7
lo iI
a i
sg
1~
a
O
47-101
Figure 1-1. ASB-125/60 radio installation
1-2
UNITS
FIG.
DESCRIPTION PER
INDEX I PART
ASSY
NOi NO.
RADIO INSTL (ASB-125/60) 1

1-1- 369B90144-501
369B90144-503 RADIO I~JSTL (ASB-125/60) (PROVISIONS FOR INSTL)... 1
369H90144-505 RADIO ZNSTL (ASB-125/60) (PROVISIONS FOR MSTL)... 1

I CIRCUIT BREAKER 1
-1 2CT13-15
-2 MS90311-231 SMrITCH 1
SCREW 2
-3 1 SFSWGC8D-M1BK
COVER 1
-4 369H90 144-13
AC31C I ANTENNA SET (NHA 3691190144-501 AND -33)..... 1
SCREW (NHA AC31-2) 4
-5 NO NUMBER i
AC31-2 I CONTROLHEAD (NHA ACS1C) 1

-6
NAS173884-2 I RIVET............. 2
-7
NAS173884-1 RIVET............ 4
-8
BRACKET 1
-9 369B90144-11
1 BRACKET 1
-10 369B90144- 12
-11 MS20426AD3 I RIVET 6
RECEPTACLE 4
-12 PRG 3-1/2
MS21059-06 NUTPLATE.. 2
-13 i........
-14 MS21266-1N GROMMET 1
ASB-125/60 COMMUNICATIONS TRANSCEIVER SET

(NHA 3691190144-501) 1
-15 99681/99718 RECEIVER/EICCITER (]RE-1200 28V/RE-60 28V)

1
(NHA ASB-125/60)
NAS517-2-0 I SCREW 4
-16
NUT...... 1
-17 MS20143-08
WASHER 1
-18 AN960PD8 L
SCREW.... 1
-19 NAS517-2-0
DUST COVER (NHA ASB-125/60)..... 1
-20 10121
SCREW 2
-21 NAS623-3-2
RIVET (ALTERNATE PART) 2
-22 NAS173884-2
WASHER 2
-23 AN960PD10L
BRACKET 1
-24 369B90144-9 1
NO NUMBER POWER AMPLIFIER/POWER SUIPPLY INSTL
1
(SEE FIG. 1-2 FOR BRKDN)
NO NUMBER SWR SENSOR AND ANTENNA INSTL
1
(SEE FIG. 1-3 FOR BRKDN)
WIRE HARNESS (RECEIVER POWER) 1
3691190144-25
CONNECTOR...... 2
UG-88/U
WIRE HARNESS (EXCITER POWER) 1
369H90144-27
CONNECTOR 1
UG-88/U
CONNECTOR 1
UG-536/U
WIRE HARNESS (SWR SENSOR POWER) 1
369H90144-29
CONNECTOR...... 1
UG-88/U
CONNECTOR....... 1
UG-203/U
369B90144-31 WIRE HARNESS (RECEIVER/EXCITER TO POWER
AMPLIFIER/POWER SUPPLY INTERCONNECTION) 1
CONNECTOR (SUPPLIED WITH ASB-125/60) 1
14996
74726 CONNECTOR (SUPPLIED WITH ASB-125/60) 1
HYTIP 5
MPCMB0M-1-12 i.
TERMINAL 2
MS25181-1
SOLDER SLEEVE 7
D121
TERMINAL 2
MS2 503 6- 153
TERMINAL. 2
MS25036-108
TERMINAL.... 2
MS25036-103
TERMINAL 11
MS2 503 6 -10 1
NO NUMBER WIRE HARNESS (CONTROL HEAD TO TB102)
1
(SUPPLIED WITH ACS1C)
1-3
7
8
I/ I;
a
C
c\
s~
12
~10 v 7 17
1 16
I\,_pJ~I
OO
o
O
I 11
n~ ~Y ~16
e
~15
;i
32 24
22 1
33 3
27
6
4--~- r
Il
i.
.~.J :k_,I
Ti~ c
1
I ~30
o
Y Y
o
t;I.
22
41-108
Figure 1-2. Power amplifier/power supply installation
1-4
FIG. UNITS
NO. NO. ASSY
1-2- NO NUMBER POWER AMPLIFIER/POWER SUPPLY INSTL

(SEE FIG. 1-1 FORNHA) REF
-1 HS621-7 I COVER 1
-2 MS2 1043-06 1 NUT 7
-4 MS2 1043-04 1 NUT 2
-5 1 MS24693-3 SCREW 2
-6 MS27212-1-7 TERMINAL 1
-7 1 NAS601-8 SCREW 2
-8 1 MS35333-37 WASHER 2
-9 NAS600-4 I SCREW 2
-10 MS3 5333 -36 WASHER 2
-11 99683 1 POWER AMPLIFIER/POWER SUPPLY (PA1O1OB 28V)
(NHA ASB-125/60, FIG. 1-1) 1
-12 MS20470AD5-3 1/2( RIVET 4
-13 10179 SIDE MOUNT PLATE (NHA ASB-125/60, FIG. 1-1) 1
-14 NO NUMBER DUST COVER (NHA ASB-125/60, FIG. 1-1) 1
-15 MS2 1043-08 I NUT i 16
-16 AN960PD8 L WASHER 32
-17 NAS623-2-4 SCREW 16
-18 99916 1 SHOCKMOUNT (NHA ASB-125/60, FIG. 1-1) 1
369H92052 AMPLIFIER BRACKET INSTL 1
-19 NAS603-7 I.. SCREW .i............................. 1 4
-20 AN960PD10L I.. WASHER 1 4
-21 369B92052-9 1 BASE PLATE 1
-22 MS20470AD3 I.. RIVET 24
-23 369H92052-8 1.. CLIP 1
-24 369B92052-7 1.. CLIP 1
-25 369B92052-15 1.. CLIP 1
-26 369B92052-13 1.. CLIP 1
-27 369B92052-12 1.. CLIP 1
-28 369B92052-11 1.. CLIP 1
-29 MS20470AD3 I.. RIVET AR
-30 1 MS20426AD3 RIVET 8
-31 MS21059L3K NUTPLATE 1 4
-32 369B92052-5 1.. BRACKET 1
-33 369B92052-3 1.. BRACKET I 1
1-5
9
s ui -I~ \;?V-!,"ri;l i
-.I~ b
FE_;.~
j c"~;i;:,,;, /i
,T
1E
:1
O
47-109
Figure 1-3. SWR sensor and antenna installations
1-6
FIG. UNITS
INDEX PART I DESCRIPTION PER
NO. NO. ASSY
1-3- NO NUMBER SWR SENSOR AND ANTENNA INSTL

(SEE FIG. 1-1 FORNHA) REF
-1 NASGO 1-6 1 SCREW 4
-2 AN960D6 I WASHER 8
-4 AC31-3 SWR SENSOR (NHA ACJ1C, FIG. 1-1) 1
-5 MS204 70AD3 RIVET 1 15
-6 369B90144-15 DOUBLER 1
-7 MS3 5490- 11 GROMMET I 1
-8 MS20470AD3 RIVET 1 6
-9 369B90144-17 DOUBLER 1
-10 NO NUMBER SETSCREW (NHAACS1-1) 1
-11 NAS1105-4 BOLT 2
-12 AN9 60PD516 L WASHER 2
-13 NO NUMBER BOLT (NHA AC31-1) 4
-14 MS33538-104 WASHER 4
369B90144-33 1 ANTENNA ASSY (NHA 369H90144-501 AND -503) 1
UG-88/U I.. CONNECTOR 1
MS2 503 6 10 1 I TERMINAL 1 7
-15 AC31-1 I.. ANTENNA I 1
-16 MS20470AD3 RIVET 30
-17 369B92051 BRACKET 1
1-7/1-8
SECTION 2
2-1. GENERAL ~FORMATION. The ASB-125 low-level SSB or AM outputs which are supplied
and ASB-60 radio installations are 10-channel to the power amplifier for amplification to broad-
(ASB-125) and g-channel (ASB-60) single side- cast power. The receiver/exciter is contained
band (SSB) and compatible amplitude modulated in a single unit which is enclosed in a dust cover
(AM) transceiver systems. The radio installa- and mounted on the instrument panel. The front
tion is used for long range voice communications panel of the unit contains controls and indicators
in the 2 to 18 MIIe frequency range. The radio for operation of the radio system. Refer to the
installation receives +28 vdc, at 7.5 amperes manufacturers publication (table 2-2, HMI
maximum, operating power from the main power Vol 1) for a detailed description of the unit.
bus through the 15-ampere SSB (RADIO HF) cir-
cuit breaker (CB122) on the instrument panel. 2-3. DESCRIPTION OF PA-1O1OB POVIIER
Figure 2-1 shows the wiring diagram for radio AMPLrFT-~ER/POWER. SUPPLY. The power amp-
system. Radio installation equipment is supplied lifier of the PA-1O1OB power amplifier/power
in three configurations: part number 369B90144- supply (11, fig. 1-2), part number 99683, ampli-
501, the equipment as installed at the factory and fies the low level signal from the exciter to a
369B90144-503 and -505, the provisions (com- power level of 125 watts peak envelope power
ponents, wire harness, cables, and hardware) (PEP) for SSB operation, or 30 watts average for
required for field installation, but without the AM operation, and supplies the amplified signal
radio set (-503, -505) or the antenna set (-505). to the 50-ohm antenna for transmitting. The
The major components supplied with each of the power supply converts the 28 vdc input to voltages
three configurations are listed in table 2-1 and required for operation of the radio system. The
described in following paragraphs. power amplifier/power supply is contained in a
single unit which is shock-mounted in the avionics
NOTE: Refer to the manufacturers publica- compartment beneath the pilots compartment
tion (table 2-1, HMI Vol 1) and to Federal floor. Refer to the manufacturers publication
Communications Commission (FCC) regula- (table 2-2, HMI Vol 1) for a detailed descrip-
tions for information on legal requirements tion of the unit.
and limitations applicable to transmitting
SSB and AM signals. Also, note that an inte- 2-4. DESCRIPTION OF AC31-1 ANTENNA. The
grated interphone communication system AC31;1 antenna(l5, tig. 1-3) is a center-loaded

(ICS) must be installed in the helicopter for rf whip antenna which may be remotely tuned to
use with the radio installation. The ICS resonance at any operating frequency within its
audio equipment (headset, microphone, two-octave tuning range. The antenna consists
switch and jack assembly, and control unit) of three main sections: the whip, the body, and
are required for reception and transmission the base. The body consists of an outside fiber-
of voice communications. The electrical glass tube and a thin-walled inner tube on which
the tuning coil is wound. A core, composed of
interface of the radio and ICS is shown in
figure 2-1, and the ICS electrical circuitry powdered iron and copper tuning slugs, is moved
is described in the ICS Opt Eqpt Manual within the coil by a de motor and gear drive in
i). the base tube. The motor drive consists of a
(table 21-1, HMI Vol
permanent magnet de motor and two nylon reduc-
2-2. DESCRIPTION OF RE-1200/600 tion gears turning a threaded rod. A block riding
RE Of the on the threaded rod is coupled to the tuning slug
RE-~2001600 receiver/exciter (15, fig. 1-1), by an insulated pushrod. Travel of the block is
part number 99681/99?18, receives and demodu- limited to seven inches by limit switches which
lates either SSB or AM radio-frequency inputs break the power to relays in the control unit,
and presents the audio to two MIKE RF jacks and thereby interrupt the power to the motor.
and two PHONE RF jacks (369B90144) or to the A loop of nichrome wire is mounted so that as
ICS audio circuitry (3691190144-501-503, and the block moves on the threaded rod a shorting
-505). The exciter converts voice inputs to contact changes the resistance of the circuit.
2-1
Table 2-1. Major components of radio installations
Configuration Part No. 369B90144
Equipment -501 -503 -505
Receiver/Exciter" 99681 or 99718
Microphone None
Power Amplifier/Power Supply* 99683
Antenna** AC31-1 AC31-1
Control Head* AC31-2 AC31-2
SWR Sensor*" AC31-3 AC31-3
*Part of ASB-125/60 Radio Set.

**Part of AC31C Antenna Set.
The motor drive and coil assembly slides into the level dip of the meter needle. This indicates that
base tube and body of the antenna and is sealed and the antenna is tuned to the receiver/exciter fre-
anchored by tightening three screws which expand quency. The control head is secured to upper and
a rubber gland at the bottom of the base tube, lower brackets inside a thermo-plastic cover that
The antenna is tuned by using controls and indica- is mounted on the left side fairing of the instru-
tora on AC31-2 control head (6, fig. 1-1) to oper- ment panel. Refer to the manufacturers publica-
ate the de motor and position the core. The tion (table 2-2, HMI Vol 1) for a detailed descrip-
antenna is mounted on the right forward underside tion of the control head.
of the helicopter beneath the pilots compartment,
with the whip extending forward. Refer to the 2-6. DESCRIPTION OF AC31-3 ASW SENSOR.
manufacturers publication (table 2-2, HMI The
Vol 1) for a detailed description of the antenna, in series with the antenna cable to measure the
ratio of transmitter power output to reflected
2-5. DESCRIPTION OF AC 31-2 CONTROL power. The sensor delivers a voltage propor-
tional to this ratio to the SMrR meter in the control
contains controls, indicators, and circuitry which head for visual display for use in fine tuning the
enable the operator to accurately tune the antenna antenna. The SWR sensor is mounted with a
to the frequency of the receiver/exciter. The doubler to the lower support structure for the
control head has a meter which has a FREQ instrument console in the avionics compartment
(frequency) scale for approximate tuning and a beneath the pilots compartment floor. Refer to
SWR scale for fine tuning. The variable resist- the manufacturers publication (table 2-2, HMI
ance in the antenna forms one arm of a bridge Vol 1) for detailed description of the SWR sensor.
circuit in the controlhead. The circuit provides

a reading related to the
tuning slug position, so 2-7. Informationonheli-
the meter can be calibrated directly in frequency. copter components that interface with the radio
Fine tuning is accomplished by switching to a system is in HMI Vol 1 and 36913 IPC. For
SWR scale on the same meter. The meter is then information on associated optional avionics equip-
operated by an external SWR sensor placed in the ment used with the radio system, refer to the
coax line to the antenna. This sensor has con- applicable Opt Eqpt Manual for that specific equip-
stent sensitivity over the antennas frequency ment (Section 21, HIVII Vol 1).
range and, once set up for an installation, re-
quires no further adjustments. The FREQ/ANT 2-8. TROUBLESllOOTlNC. If the radio
system
switch is set to the frequency of the channel se- does not operate properly during operational
lected for radio receive or transmit operation, check or normaluse, refer to table 2-2 for aid
Then, the switch is set to SWR and while operat- in locating the probable trouble and for corrective
ing the radio to transmit a carrier or tone, the action. Refer to the wiring diagram (fig. 2-1)
ANT TUNE control is rotated to obtain the lowest for aid in troubleshooting. The troubleshooting
2-2
procedures are based the assumption that the

on 2-12. REPLACEMENT OF AC31-2 CONTROL
radio set is being operated properly, and that all HEAD;
electrical connectors are connected securely.
If troubleshooting indicates that the trouble is in CAUTION: Check that all electrical power
the radio set or the antenna set, refer to the is OFF.
applicable manufacturers publication (table 2-2,
HMI Vol 1) for unit troubleshooting and correc- a. Remove screws (3, fig. 1-1) and cover (4).
tive action. 6. Disconnect SWR cable plug from control
head (6).
NOTE: reproduced by
The radio audio is c. Disconnect wires from terminal board TB1
components of the integrated interphone oncontrol head (6).
communication system (ICS) which, in itself, d. Remove screws (5) and control head (6).
may be the source of audio trouble. When e. Install replacement control head in reverse
audio malfunction is encountered, refer to order of removal.
the ICS Opt Eqpt Manual (table 2-21, HMI
Vol 1)for troubleshooting procedures for 2-13. REPLACEMENT OF ASB-125/60
that portion of audio circuitry. RECEIVER/EXCITER.
2-9. OPERATIONAL CHECK. Anoperational CAUTION: Check that all electrical power
checkshouldbe performed any time a malfunction is OFF.
is suspectedand prior to normal operation follow-
ing repair. Refer to the manufacturers publica- a. Disconnect three electrical connectors from
tion (table 2-2, HMI Vol 1) for the antenna set rear of receiver/exciter (15, fig. 1-1).
and the radio set for procedures and perform the b. Withdraw receiver/exciter from dust
following operational checks: cover (20).
a. Antenna Set c. Install replacement receiver/exciter in
(1) Frequency Scale Adjustment reverse order of removal. See figure 2-1 for
(2) Tuning Motor Speed wiring and cable connections.
b. Radio Set
(1) Channeling 2-14. REPLACEMENT OF ASB-125/60 POWER
(2) Transmitter Output AM AMPLIFIER/POWER SUPPLY.
(3) Transmitter Output SSB
(4) Sidetone Volume CAUTION: Check that all electrical power
(5) Squelch is OFF.
(6) Audio Volume
(7) Clarifier a. Gain access to avionics compartment be-
(8) Interference neath pilots compartment floor.

b. Disconnect four electrical connectors from
2-10. ALIGNMENT. Refer to the manufacturers rear of power amplifier/power supply (11, fig. 1-2).
HMI Vol 1) for align- c. Remove wing nut and plate from shock
ment procedures for the radio set, mount (18), and remove power amplifier/power
supply (11) along with attached dust cover (14) and
2-11. R~SPECTION. aidindeterminingthe
To side mount plate (13).
extent of repair and replacement required, in- d. Remove screws (7, 9) and washers (8, 10),
spect the components of the radio system in an~i remove dust cover (14).
accordance with FAA AC 43.13-1A, standard e. Install replacement power amplifier/power
avionics maintenance practices, and the following: supply in reverse order of removal, See figure
a. Inspect all components for corrosion and 2-1 for wiring and cable connections.
obvious physical damage.
Inspect the receiver/exciter, power ampli-
b.
2-15. REPLACEMENT OF AC31-3 SWR
fier/power supply, controlhead, antenna base, SENSOR.
and wire harness for evidence of electrical over-
heating.
c. Inspect the receiver/exciter and control CAUTION: Check that all electrical power
he~ for loose or missing control knobs, damaged is OFF.
or obscured markings, and damaged indicator
glass. a. Gain access to the avionics compartment

beneath the pilots compartment floor.
d. Inspect damaged connectors,
for loose or
loose or missing mounting hardware, and worn b. Disconnect two electrical connectors from
or frayed wiring insulation. SWR sensor (4, fig. 1-3).
2-3
Manual CSP-080
Section 2 Opt Eqpt
Table 2-2. Troubleshooting

Symptom
SSB circuit breaker Momentary overload. Reset breaker to ON.

trips.
SSB circuit breaker trips Overload or short in power Repair or replace faulty
amplifier/power supply or unit.
following reset.
receiver/exciter.
Short in wire harness. Repair or replace wire

harness.
Control head frequency Defective antenna tuning Repair or replace antenna.

meter pointer does not mechanism.
move during coarse
tuning. Defective meter. Repair or replace control

head.
No 28 vdc present at Trace power circuit and

antenna. repair or replace as
required.
Antenna fuse open. Replace fuse.

Control head frequency
meter pointer has exces-
sive overshoot during Antenna motor speed Adjust antenna motor speed.
fine tuning. excessive.
Control head SWR meter Radio not transmitting AM Switch radio to AM mode.
does not dip during fine signal.
tuning.
Defective antenna tuning Repair or replace antenna.
mechanism.
Defective SUrR sensor of Repair or replace SWR

meter. sensor or control head.
Radio transmission weak Exciter or power amplifier Align or adjust as
out of adjustment. required.
Defective exciter Repair or replace defec-

or power
amplifier. tive unit.
Audio weak at full volume, Receiver out of adjustment. Align or adjust receiver.
ICS o. k.
Radio transmitter and Defective power supply. Repair or replace power

receiver in-operative, supply.
ICS o. k.
Defective wire harness. Repair or replace wire
harness.
2-4
c. Disconnect two wires from terminal board NOTE: Add washers (14) as required to
on mvR sensor (4). fill gap between clamp halves before
d. Remove screws (1) and washers (2, 3), and tightening bolts (13). Tighten setscrew (10)
remove SWR sensor (4). to ensure electrical contact between clamp
e. replacement SWR sensor in reverse
Install and antenna.
order of removal. See figure 2-1 for wiring and
cable connections.
2-17. ADJUSTMENT. Refer to the manufac-
2-16. REPLACEMENT OF AC31-1ANTENNA. turers publication (t~able 2-2, HMI Vol 1) for
the radio set and the antenna set for adjustment
CAUTION: Check that all electrical power procedures.
is OFF.
a. Gain access to the avionics compartment 2-18. REPAIR. Refertothe manufacturers

beneath the pilots compartment floor. 2-2, HMI 1) for the
Vol
b. Remove cover (1, fig. 1-2) from terminal radio set and the antenna set forperiodic main-
board TB102. tenance and repair procedures. Replace defec-
c. Disconnect seven wires of antenna cable tive cables, wiring, and attaching and mounting
from TB102. parts with new parts.
d. Disconnect antenna cable connector from
SW~ sensor (4, fig. 1-3).
e. Remove grommet (7) and pull antenna 2-19. WIRINGDIAGRAM. Seefigure a-1for
ca5Sles through hole in doubler (9). the radiosystem interconnecting diagram.
f. Remove bolts (13), eashers (14), clamp Refer to the manufacturers publication
haiires, and antenna (15). (table 2-2, HMI Vol 1) for the radio set
ff. Install replacement antenna in reverse and the antenna set for interval schematics
order of removal. See figure 2-1 for wiring and wiring diagrams for components of the
and cable connections. sets.
2-5/2-6
Opt.Eqpt Manual Section 2
r RECEIVER RF
INP1OA ASB1A
HF COMM RECEIVE RF CABLE (RG-58CiU)
HF COMM XMIT RF CABLE (RG-58C/U) py(

P3A
J3 RCVR
MCITER RF OUT JlOt~-- ASB2A J1D(CITER

58 P8A (NOTE 4)1
POWER AMPLIFIERI
RECEIVERID(CITER B
C POWER SUPPLY
DIMMER (PANEL LAMPS)I W

E
GRAY OR ASB4A22
*T8502-78
P4A !J4
(NOTE 4) AMP TO SWR SENSOR RF
F BRNWHTORASB 1 I I CABLE(RG-58CIU)ASB3A
H REDIWHT OR ASB6A16 12
PA CHANNELING I I J C- ORNIWHT OR ASB7A16 3 PA CHANNELING
K C- YBIWHT OR ASB8A16 4 HF STANDING WAVEI
L GRNIWHT OR ASB9A16 ANTENNA
5 RATIO (SWR)
ON-OFF I M C--- BRN OR ASB1OAn 6 ON-OFF I I DETECTOR
OVEN HTRS I DDt- ORN OR ASBllA22 lDl OVEN HTRS
A+(+28VDC) REC-MC SC--WHTORASB12A16 121 A+(+28 VDC) REC-MC
C- BLKIWHT OR ASBUA16 ANTENNA CABLE
AM CONTROL V 161 AM CONTROL 521 P2A ~P CALI B
ALC P WHTOR ASB14A20 (SH) (RG-58CIU)
8 ALC RF OUT XMIT LOAD
METER R WHT OR ASB15A20 (SH) 9 METER(+) SWR V
GND T BLK OR ASB16A14 14 OUT
OPEN-ENDED SHIELD
Mlcnuololu~ GRAYORASB17A20(SH)
~*TB502-2D ASB15B20N I(I I I I ANTENNA
(TOMICROPHONES) CONTROL
VHF XMIT MIC AUDIO HI
(NOTES 5.6) ~ASBZ4A14NORBLK 15 1 L
CABLE
VIOLET OR
TB502-1F GND
VHF XMIT MIC KPI (GND) IN TB102
I
MIC Kf( N IL-- RED OR ASB19A22 RED BLU
71MIC KEY
X ASB25A20 --t<7~t-- BLK AWG 20
Z
ASB26AM --S(s~- WHT AWG 20
*TB101
90000~
P506X14
7
SSB
CB122
15A
WHT OR
WHT OR P522A14
HF COMM SWR DETECTOR CABLE

SWITCHED A+i
(+28 VDC)IN
A+(+28 VDC) IN j ASB27A22
ASB28A22
----Ks~t--
ASB29An --t(s~-- RED AWG 22
ASB30An 7~-
BLUE AWG 22
GRN AWG 22
BLKIWHT AWG 22
+28 VDC BUSi I I ASB31A22 ORN AWG 22
SP
HF COMM CONTROL HEAD TO ANTENNA CABLEI
MT PWR cBAT
,k
"MAIN POWER
SWITCH S2
GND
GND ASB22A20N -O
+28 VDC PWR IN
FUSE PIN-RED
ANTOUNA 0.75A .SWR PLUG
NOTES:
+SWR V IN 1. THIS WIRING DIAGRAM SHOULD BE USED WITH THE APPLICABLE ELECTR ICAL
HEAD 5. INTERCONNECTION WIRING FROM CONNECTOR P8 TO MICROPHONE JACKS IS AS FOLLOWS;
ASB23A20 (TW
SYSTEM WIRING DIAGRAM IN THE HMI FOR COMPLETE CIRCUIT IDENTIFICATION.
OPEN-ENDED SHIELD
TS-I--I II SHELL-BLU 2. ASTERISK INDICATES PART OF HELICOPTER BASIC ELECTRICAL SYSTEM.
(ASB17
ANTENNAMOTORVOUT(I, II
;r)StASB25A20 A
1
3. ABBROIIAIIONS:
HTRS -HEATERS SP-SPLICE
UN MICJACK
(SWITCHCRAFT S12B)
+28 VDC IN FROM PA POWER AMPLIFIER TS TERMINAL STRIP PIO P8
RETRACT LIMIT SW ASB27A22 A
PS POWER SUPPLY TW PR TWISTED PAIR MIC JACK
+28 VDC IN FROM SH SHIELD
ASB28A22
MT LIMIT SW
a WIRING CONNECTORS P8A AND P4A M PART OF WIRE HARNESS
+28 VDC OUT
j
ASSEMBLY. IF THE ASSEMBLY IS A MODIFIED PART NO. 84228 WIRE HARNESS 6. FOR WIRINGINTERCONNECTIONS, REFER TO INFORMATION IN ME OPTION MANUAL FOR
FREQMETERVHII (i~ WIRES ARE COLOR CODED AS SHOWN; OTHERWISE WIRE NUMBERS LISTED APPLY. ME INTEGRATED INTERPHONE COMMUNICATION- SYSTEM.
FREP METER V LO
41-~f0
Figure 2-1. Radio installation interconnection 7nriring diagra~n
2-7/2-8
CSP
023

and
with initial Installation Instructions
FOR
CYCLIC STICK GRIP KIT INSTALLATION
PartNo. 369B90129-31
Part No. 369B90129-505
Hughes nelicopters.wm
C~D775150 Issued 1 June 1977

IVI FG I
INTRO
RECORD OF REVISIONS
CSP-023
MFG REV
~kp
CSP-023 Opt EQpt Manual Table of Contents
CVCLIC STICK GRIP KIT
TABLE OF CONTENTS
Section P;i~e
FOREWORD F-l

of this Manual F-l
F-3. Compatibility of Com-
bined Optional
Equipment F-l
Contents. F-l
F-5. Use of this
Manual............. F-l
F-6. Related Publications.... F-l
and Revisions ........F-l
1 ILLUSTRATED PARTS LIST ....1-1
1-1. Scope and Contents.....l-r

1-2. Group Assembly
Parts List...........l-l
1-3. Illustrations .........1-1
2-1. Generallnformation ....2-1

2-2. Description ..........2-1
2-3. Reference Data .......2-1
2-4. OperationalCheck .....2-1
2-5. Replacement of Cyclic
Stick Grip Switches.....2-l
2-6. Wiring Diagram.......2-l
3-1. GeneralInformation ....3-1

3-3. Preparation..... .....3-2
3-4. Removal of
Cyclic Stick..........3-2
3-5. Disassembly of
3-6. Assembly of Cyclic
Stick Grip Kit 3-2
3-7. Installation of
3-8. Weight and Balance.....3-3
CSP-023 Opt Eqlpt Manual Foreword
FORMIORD
F-l. PURPOSE AND CONTENT OF THIS organized to provide comprehensive coverage of

MANUAL. This manual supplements information entire systems, major equipment groupings, and
contained in HMI Vol 1 and 3691) IPC, and major components that are similar or associated.
contains instructions for initial installation and (Procedu.res for each of these are presented in
continuing maintenance for the cyclic stick grip sequence as defined in Section i, HMI Vol 1.)
kit assemblies. Weight and balance data is
included. This manual also contains parts lists F-5. USE OF THIS MANUAL. This manual is for
for procuring replacement parts for the cyclic u.se by operators of the Model 369D helicopter
stick grip kit assemblies, equipped with a cyclic stick grip kit. Although
this manual is a separate publication, it should be
F-2. APPLICABILITY. The cyclic stick grip kept with HMI Vol i, HMI Vo12, 369D IPC
kits applicable for any Hu~hes 500D and other handbooks listed in Section
are use on
1, HMI
(Model 369D) helicopter. Vol 1 that form the primary information file for
the helicopter.
OPTIONAL EQUIPMENT. For compatibility F-6. RELATED PUBLICATIONS. Reference is
information which optional equipment may or
on made to applicable portions of HMI Vol 1 and
may not be used in combination at the same time, 369D IPC as required to accomplish instructions
refer to Section 21, HMI Vol i. contained herein.
F-4. ORCANIZATIONOF CONTENTS. The con- F-7. LITERATURE CHANGES AND REVISIONS.
tents of this manual are grouped into sections as Changes and revisions to contents of this manual
ou.tlined in the Table of Contents. Each section is are made as defined in Section 1, HMI Vol 1.
F-1/F-2
SECTION 1
1-1 SCOPE AND CONTENTS. This illustrated lists furnish information for procuring replace-
parts list provides, by means of text (parts lists) ment parts for the cyclic stick grip kits, and
and companion illustrations, a complete parts shall not be used for any other purpose. (For
definition of the 369B90129-31 and 369H90129-505 information or procurement of replacement parts
Cyclic Stick Grip Kits, manufactured by Hu.ghes for the standard cyclic stick refer to 369D IPC.)
Helicopters, Cu.lver City, California.
1-3. ILLUSTRATIONS. An isometric illustration
NOTE: The illustrated parts list is organized is providedand includes acombined parts list,
and presented in the same manner as the 369D with variations noted, for both the 369B90129-31
Series Illustrated Parts List (369D IPCJ. (For and 369B90129-505 cyclic stick grip kits. The
information on use, refer to the 369D lPC.) illustration is exploded to the extent necessary
to show the parts relationship for the complete
1-2. GROUP ASSEMBLY PARTS LIST. The parts cyclic stick grip kits.
1-1
Section 1 Opt Eqpt Manu.al CSP-023
2
;x
_r~
i
12
n~
~I
-I
17 (B
a,t
~it\s
~I
I
i. .s
41-189
Figure 1-1. Cyclic stick grip kit assembly
1-z
as Received
A~$
FIG. I I I UNITS
NO. NO. ASSY
1-1- 3691190129-31 CYCLIC STICK GRIP KIT (Complete assy) REF

369H90129-505 CYCLIC STICKGRIP KIT (Griponly) I REF
-1 XMRA20-0000F GASKET 1
-2 MS1-7803-16-20 PIN (Componentof 369B90129-31) 20
MS100-2520P PIN (Componentof 3691190129-505) 20
-3 MRAC20P-JTC6H9 PLUG (Component of 369B90129-31) 1
-4 22K1-048 NUT (Component of 369B90129-31). 1
-5 MS24665-151 1 PIN, COTTER (Component of 369B90129-31) 2
-6 HS626-4-326 BUSHING (Componentof 3691190129-31) 1
-7 1~1820365-832 1 NUT 1
-8 AN9 60PD8 L I WASHER 2
-9 11~827039-0824 SCREW 1
-10 MS17821-1-9 I STRAP 1
-11 TC-826 I MOUNTINGPLATE, STRAP (Component of 1
3691190129-31)
-12 369B90153 GRIP, CYCLIC STICK 1
-13 NAS1398B5-4 RIVET (Component of 369B90129-31) 7
-14 369D27132 TUBE ASSY (Component of 369B90129-31). I 1
-15 NAS561P2-5 PIN (Component of 369B90129-31) 1
-16 AN960PD516L WASHER(Componentof 369H90129-31) 1 4
-17 MS20470B3 I RIVET (Component of 369H90129-31) 1
-18 1369A7129 STUD (Component of 369B90129-31) 1
-19 369A7141 SOCKET (Component of 369B90129-31) 1
1-3/1-4
SECTION 2
2-1. GENERAL INFORMATION. A special CAUTION: Do not activate emergency float

cyclic stick grip assembly is provided for use switch or hoist cable cutter switch.
when a combination of the cargo hoist/hook and
h. If installed, check operation of emergency
emergency float kits are installed on the helicopter
at the same time.
float and cargo hook/hoist switches in accordance
with the applicable Opt Eqpt Manual.
2-2. I)ESCRIPTION. Remove electrical power; place BATT-OFF-

The cyclic stick grip kit
EXT switch in OFF position.
may be procured in two forms. The369H90129-31
kit contains a complete pilots cyclic stick assem-
2-5. REPLACEMENT OF CYCLIC STICK GRIP
bly. The 3691190129-505 kit contains only the
stick grip and required parts for installation on
SWITCHES (see Figure 2-1).
the existing pilots cyclic stick. Each cyclic grip a. Check that all electrical power is OFF.
kits provides a four-way cyclic trim switch, a NOTE: Disassemble only to the extent required
two-position trigger type communication switch, for the replacement of damaged or defective
and two guarded button switches for emergency switches. The wiring through the grip assembly
floats and cargo hook or hoist installations. A is tied with nylon cord (7, table 3-1) and
plug covers an opening which may be used for an covered with an insulating sleeve. Do not
additional switch if required. remove twine ties or insulating sleeves unless
wire replacement is required.
2-3. REFERENCE DATA. Maintenance of the
cyclic stick grip kits is similar to that of the b. Remove screws securing affected switches.
standard cyclic stick and grip (Section 7, HMI c. Unscrew RADIO/ICS triggerswitch pin and
Vol 1). Refer to Section 20, HMI Vol 1 for carefully withdraw pin while holding switch in
interfacing schematic and wiring diagrams. place.
Differences in the grip switches and electrical d. Unsolder wiring terminals on switch to be
wiring are discussed in the following paragraphs, disconnected. If more th~ul one switch is to be
replaced, tag wires to ensure correct reinstalla-
2-4. OPERATIONAL CHECK. tion.
a. Place BATT-OFF-EXT switch in the OFF e. Solder
wiring to terminal of replacement
position. Ensure that all electrical power is off, switches applicable. Remove any wire identi-
as
b. Disconnect electrical plug located near fication tags.
floorline aft of pilots cyclic stick, f, Insert replacement switch in grip mounting
c. Using ohmmeter, conduct continuity check receptacle; secure switches using original attack-
of all switch circuits to ensure properhookup of ing hardware.
wiring and for switch operation.
d. Connect electrical plug to receptacle; safety NOTE: Make certain switch is properly
with lockwire (3, table 3-1). positioned with applicable keyway, pin hole,
Energize electrical system. etc, for proper alignment of matering parts.
Check operation of four-way trim switch by
momentarily activating switch and checking that 2-6. WIRIl\TGDIAGRAM. Figure 2-2 contains
both lateral andlongitudinal trim actuators a wiring diagram for the
cyclic stick grip kit
operate properly. installation. Refer to Section 20, HMI Vol 1
g. Check operation of RADIO/ICS switch as for wiring information on interfacing helicopter
applicable to installed communications systems. electrical systems.
2-1
_t
CYCLIC TRIM SWITCH (S1D7)

TRIGGER PIN
HOOK SWITCH
(S4) AND GUARD
FLOAT INFLATEI
HOIST CUTTER
SWITCH (SllS5)
XM ITIICS TR IGGER
AND GUARD
SWITCH (S1121
PLUG BUTTON
GRIP ASSEMBLY
47-190
Figure 2-1. Cyclic stick grip switches replacement

2-2
CYCLIC STICK GRI P
P130
R F-------4-20
S 6-20
X F-------5-20
~b, ~Nslo7
TRIM
SWITCH
V 1--~---- 7-20
U 8-20
XMIT _2ND POS

P I------ 3-20
S112
TRIGGER
ICS IST POS
W ~-1-20 SWITCH
T
COM
I
S4
Al 9-20
HOOK
1 SWITCH
E 10-20
C ,t
F ~tSt---------13-20 I
B C---~-------12-20
SllS5
D C----------------11-za HOISTIFLOAT
M 1------17-20 \I SWITCH
NOIIC INOTE)
N ~--------------15-20
H t------------18-
J 16-
NOTE:
IF THE HOIST IS BEING INSTALLED REMOVE WIRES
11-20, 12-20, 17-20 AND JUMPER FROM SWITCH SllS5
AN D CONNECT W IRES 13-20 AND 14-20 AS SHOWN
47-191
Figure 2-2. Wiring diagram cyclic stick grip kit
2-3/2-4
SECTION 3
3-1. GENERAL II\JFORMATION. The cyclic stick to receive any combination of the above mentioned
grip kit must be installed
any Hughes 500
on optionalkits. Information in the installation
Model 369D Series Helicopter when a combination instructions is presented as additional procedures
of the 369B90065 cargo hook kit, 369B90070 hoist over and above those given in the body of the
kit, and/or 369B90121 emergency float kit are Handbook of Maintenance Instructions(HMI- Vol 1).
installed on a helicopter. Reference is made in the instructions to the
applicable data in H1MI Vol 1 that is to be
followed in order to accomplish the installation
Two configurations of the cyclic stick grip kit are
of a cyclic stick kit.
offered, the 369B90129-31 and the 369B90129-505.
The 369B90129-31 kit consists of a factory assem-
3-2. REFERENCE DATA. Table 3-1 lists
bled cyclic stick which is ready to install with a
consumable materials and expendable items
minimum of labor, whereas, the 369B90129-505
kit consists of all the components ne~essary for required for installation. Items listed in the
consumable materials and expendable items table
the owner or operator to assemble and install a
are recommended items and are of a commercial
cyclic stick grip on the helicopter.
nature that may be procurable locally. Alternate
but equivalent items are acceptable. Table 3-2
Procedures as given are to be utilized for install- lists special tools and equipment required to
ing a cyclic stick kit on a helicopter designated accomplish installation.
Item Commercial Product

No. Material Sp ec ific ation Name/No Manufacturer
1 Tubing, MIL-I-631, Type F, 3/8 in. Commercial

vinyl form U, grade A,
class 1, category 1
2 Tubing, MIL-I-631, Type F, 1/2 in. Commercial

Vinyl form U, grade A
class i, category 1
3 Lockivire MS20995C CRES Safety Commercial

wire (3)
(diameter as
required)
4 Solder SN60WRP2 as required Commercial

(QQ-S-571)
5 Cord, No. 17 Flat Commercial

Tying Air-Teet
braid
6 Tape, CT93C Commercial

Vinyl
3-1
Table 3-2. Special tools and equ.ipment
Item Nomenclature M anuf actur er
1 Removaltool, Winchester Electronics

pin, No. 107R1001 Division of Litton Industries
Oakville, Conn.
2 Insertion tool, Winchester Electronics

pin, No. 107-1015 Division of Litton Industries
Oakville, Conn.
3-3. PREPARATION. Instructions in the follow- b. Remove standard configurationcyclic stick

ing paragraphs applicable to both cyclic stick
are grip from cyclic stick tube assembly as follows:
grip kits. Preparation for installation of a grip (1) Using contact removal tool
kit includes the following: (1, table 3-2), disconnect removable contacts
a. Identify all components removed, including from electrical plug.
hardware, to gain access to work areas. Protect (2)
Remove retaining screw and lockwasher
components from damage and contamination. from base of grip. Separate grip from stick tube
b. Disconnect battery. assembly.
(1) Check that all electrical switches are (3) Tie a "fish" string (5, table 3-1).to
in OFF position. each wire bundle to aid reassembly. Push wire
into wiring exit holes in stick socket while
CAUTION: Make certain BATT-OFF-EXT carefully pulling grip wiring from stick tube
switch is in OFF position, assembly. Remove grip and wiring.
(2)
Raise pilot compartment floor left-hand
NOTE: Leave strings in tube to assist
access door; remove screws and washers secur- in reassembly.
ing battery to mounting brackets and remove
cover.
(3) Disconnect electrical wiring harness 3-6. ASSEMBLYOFCYCLIC STICKGRIP KIT.

male connector from battery receptacle located The 3691190129-31 grip kit is shipped with as
at inboard end of battery case, many parts assembled as practical, however,
the 369H90129-505 grip kit will require assembly
3-4. REMOVAL OF CYCLIC STICK. Remove at installation. Assemble 369B90129-505 grip
the stick in accordance with the
pilots cyclic kit as follows:
following instructions: a. Remove retaining screw and lockwasher
a. Disconnect cyclic stick electrical plug from the grip contained in the kit.
located on pilots lower seat structure. b. Divide the grip kit wires into two approxi-
b. Remove the hardware that secures pilots mately equal bundles as follows:
lateral control rod to stick socket; remove split (1) Form one bundle with twisted shielded
bushing from aft bolt hole to avoid loss. wires plus five additional wires.
(2) Form a second bundle with remaining
NOTE: Retain all removed hardware, 11 wires.
less cotter pin, for reuse.
NOTE: Ensure a smooth flow of wires

c. Remove the hardware that secures the
from switch contacts in grip.
lateral friction mechanism link to the cyclic
torque tube.
d. Remove the hardware that secures the stick Cut two pieces vinyl tubing (1, table 3-1)
c.
socket to the end of the cyclic torque tube, Re- to length of cyclic stick tube/socket assembly;
move stick assembly. allow approximately g-inches excess on each
piece. Insert wire bundles from grip through
3-5. DISASSEMBLY OF CYCLIC STICK. Dis- vinyltubing. Slide tubing into grip approximately
assemble the pilots cyclic stick only if 2 -inches.
369B90129-505 grip kit is to be installed. Dis- d. Attach "fish" strings to ends of grip wire
assemble the cyclic stick as follows: bundles; carefully draw wire bundles through
a. Remove nylon strap that secures electrical stick assembly and out wiring exit holes at base
wiring bundles to base of cyclic stick assembly. of stick socket (15, fig. 1-1).
3-2
CSP-023
NOTE: Push wire bundles at grip end a. Install washers (17, fig. 1-1), pin (18), and
while pu.lling vinyl covered bundles disc on lateral friction stud (19).
b. Position cyclic stick to align with mating
through exit holes in stick socket.
holes in cyclic torque tube; insert cyclic stick
lateral friction stud into guide slot of lateral
e. Position grip assembly on cyclic stick tube
friction link.
assembly and install with lockwasher and retain- c. Attach cyclic stick to cyclic torque tube
ing screw, using original hardware and replacement cotter
f. Insert vinyl tubing (2, table 3-1) over ends
pin (5). Install bolt head aft.
of electrical wiring routed through base of cyclic
d. Install slotted bushing (6) in aft position
tube assembly socket. Trim vinyl tubing as
of lower bolt hole in stick socket (15); align pilots
necessary, lateral control rod with socket (15) and install
8 PUSh wiring slack as
much electrical
original hardware and replacement cotter pin (5).
as
possible back into the stick assembly. Secure

Install bolt head aft.
wiring to tube assembly socket with nylon strap e. Assemble balance of lateral friction
(10, fig. 1-1). mechanism components on cyclic stick friction
h. Cut electrical wiring to approximately stud as follows:
16-inches in length from center of nylon strap.
(1) Install spring retainer, spring, adjust-
i. Using solder (4, table 3-1) installcontact ment knob, and nut (4).
pins (2, fig. 1-1) to ends of electrical wiring. (2) Adjust friction knob nut (4) to stop
j. Using contact insertion tool (2, table 9-2), friction knob when spring reaches free len~th
connect pinned ends of electrical wiring to plug
(no compression) ~t1/32-inch.
(See fig. 2-2, Electrical Wiring Diagram). f. Insure sufficient slack in wire bundles
k. Wrap tape (6, table 3-1), as required between stick/socket wire exit holes and strap
around electrical wiring where 1/2-inch vinyl
mounting plate (11, fig. 1-1); install strap
tubing commences at base of cyclic stick tube
(10, fig. 1-1) over end of 1/2-inch vinyl tubing
assembly socket. and combined wire bundles.
i. Connect electrical plug to mating receptacle
safety plug retaining screws with lockwire
3-8. WEIGHT AND BALANCE. The weight and
(3, table 3-1). installation of
the 369B90129-31 or 369B90129-505 cyclic stick
3-7. INSTALLATION OF CYCLIC STICK. Install grip kits is negligible. However, record the
the cyclic stick kit (369B90129-31 or 369B90129- addition of the grip kits in the basic weight and
balance record in accordance with HMI Vol 2.
505) as follows:
3-3 /3--4
CSP
026

and
FOR
LITTER INSTALLATION
Part No. 369B90011-511

369H90011-517, 369H90011-519,
and 3691190011-531
USED ON HUGHES 500D AND 500MD (MODEL 369D) HELICOPTERS
Hughes Hclicopten,
COD775090 Issued 1 October 1977

IVI FG I
INTRO
Opt Eqpt Manual CSP-026
INSL17 LATEST CHANGED RAGES, DES1IOY IUPEISLDED rAGES.

LIST OF EFFECTIVE PAGES THE ASTERISK INDICATES RAGES CHANGED. ADDED OR DELETED BY THE CURRENT CHANGE.
Page Issue Page Issue
Title Original F-2 Blank Original

A thru B........,.,..... Original 1-1 thru 1-13 Original
C Blank Original 1-24 Blank Original
i Original 2-1 thru 2-5 Original
ii Blank Original 2-6 Blank.. Original
F-l Original 3-1 thru 3-8 Original
NUGHES TECHNICAL MANUAL RECOMMENDED CHANGE 1~EPORT
revision of this manual will be made to incorporate the latest illformation. If, in the opinion of the
revisions.
Hughes Helicopters
Attention: J. Dillon, Commercial Service Publications

2T17B
Originator
Address
Bool~ Identification: Date:
]Figclre Number(s)
nemarks/necommendatians
B/C
BECORD OF REVISIONS
CSP-026
MFG REV
RECORD OF TEMPORARY REV1SIONS
~p
p ATP REV INSERT DATE REV REMOVE
LITTER INSTALLATION
TABLE OF CONTENTS
Section Page
FOREWORD F-l

of this Manual........., F-l
F-3. Applicabilit~ F-r
F-5. Compatibility of
Combined Optional
Equipment F-l
Contents F-l
F-ll. Related Publications...... F-l
and Revisions F-l

1-3. Group Assembly
Parts List 1-1
2 MAINTENANCE INSTRUCTIONS... 2-1
2-1. General Information...... 2-1

2-4. Litter Installation....... 2-1
2-8. Litter Door Installation.... 2-1
3 INSTALLATION INSTRUCTlONS... 3-1

3-5. Removal of Helicopter
Equipment 3-1
3-7. Installation of Litter Kit
Provisions 3-1
3-9. Installation of Passenger
and Litter Door Retainer... 3-1
3-11. Installation of Stanchion
Support 3-2
3-13. Installation of High Head
Room Door Kit.......... 3-6
3-15. Installation of Litter Kit 3-6
3-17. Installation of Helicopter
Equipment 3-6
3-19. Weieht and Balance Data 3-8
FOREWORD
F-l. PURPOSE AND CONTENT OF THIS Each section is organized to provide comprehen-
MANUAL sive coverage of entire systems, major equ.ipment
F-2. This manual supplements information or associated. (Procedures for each of these are
contained in HMI Vol 1 and 369D IPC, and presented in sequence as defined in section i,
contains instructions for initial installation and HMI Vol 1.)
continuing maintenance for the litter installations.
Weight and balance data is included. This manual F-9. USE OF THIS MANUAL
also contains parts lists for procuring replace-
ment parts for the litter installations. F-10. This manual is for use by operators of
the Model 369D helicopter equipped with a litter

F-3. APPLICABILITY installation. Although this manual is a separate
publication, it should be kept with HMI Vol 1,
F-4. The litter installations are applicable for HMI Vo12, 369D IPC, and other handbooks
use on any Hughes 500D and 500MD (Model 3691)) listed in section 1, HMI Vol 1 that form the
helicopter. primary information file for the helicopter.

F-ll. RELATED PUBLICATIONS
OPTIONAL EQUIPMENT

F-6. For compatibility information on which
of HMI Vol 1 and 369D IPC as required to
optional equipment may or may not be used in
accomplish instructions contained herein.
combination at the same time, refer to section 21,
HMI- Vol 1.
F-13. LITERATURE CHANGES AND REVISIONS
F-7. ORGANIZATION OF CONTENTS
F-8. The contents of this manual is grouped into manual are made as defined in section 1, HMI
sections as outlined in the Table of Contents. Vol 1.
F-1/F-2
SECTION 1
1-1. SCOPE AND CONTENTS 1-5. ILLUSTRATIONS
1-2. This illustrated parts list provides, by 1-6. Isometric illustrations are provided for
means of text (parts lists) and companion illus- each group assembly parts list. Each illustration
trations, a complete parts definition of the is exploded to the extent necessary to show parts
litter installations manufactured
by Hughes relationship for the complete litter installation
Helicopters, Culver City, California. (fig. 1-1).
NOTE: The illustrated parts list is organized 1-7. USABLE ON CODE

and presented in the same manner as the 369D
Series Illustrated Parts List (3691) IPC). 1-8. The USABLE ON CODE column located at
(For information on use, refer to 3690 IPC.) the right-hand side of the group assembly parts
list pages indicates the effectivity of parts by
1-3. GROUP ASSEMBLY PARTS LIST aircraft serialnumber. In many cases two differ-
ent parts are listed, representing the original
one
1-4. The parts lists furnish information for installation and another representing the improved
procuring replacement parts for the litter instal- replacement item. Alphabetic codes are used to
lations and shall not be used for any other purpose. indicate the aircraft serial number applications
For information or procurement of replacement of a given part. When no USABLE ON CODE is
parts, refer to 369D IPC. listed, items are understood to have full effectivity.
1-1
Section 1
LITTER RAIL
Icl BRACKETS
i)7;jCi
~I ba
(Y~j
P
Y,
47I 5
7
32------~
i: O SHOULDER
STRAP)4:: o3E
FITTING (ROTATED)
33----L
35
I
O UPPER CENTER t
O L!TTER DOOR WITH STANDARD
WINDOW (ROTATED) 43--~a
BRACKET 35 t
42 37
LOWER
CENTERBRACKET
32
34
0 U-BfiR~!BRACKET
~i\ LOWER END
V B~I
i o 39 i
\I n
32
a as
c
34 9~
W
~----34
47-247-1
Figure 1-1. Litter kit installation (sheet 1 of 2)

1-2
30
II h if
k: Q LITTER
QUICK-RELASE PIN
a I
15
9
r i;
16------~
26O STANCH ION AND SU PPORT
27i o TRACK AND FRAME

ASSEMBLY ATTACHMENS
2! j 17
17
i
i 28
18
16
@lo.
c~ Y ~----20
22
6- ii
24t, 25
22------c3
21 15~
t
15
1
r)
II
12
13
47-247-2
1-3
FIG. UNITS USABLE

NO. NO. ASSY CODE
1-1- 3691190011-519 LITTER MIT INSTL (Complete with doors) REF

369B90011-521 LITTER KIT INSTL (Without doors) REF
-1 3691)292572 CARD ASSY, VNE 1
-2 369B90011-511 DOOR KIT, HIGH HEAD ROOM (Component of
369B90011-519) (See figure 1-2 for breakdown)
-3 369B92610 LITTER ASSY i 2
4 360B92723 1 BELT ASSY 1 8
-5 369B922 52 -9 1 SEAT BELT I 1
369B92252-7 1 SEAT BELT I 1
-6 1 3691-16513-3 SHOULDER STRAP (For replacement 2
order 369B6513-5)
-7 1 369B92253-503 SEAT ASSY 2
369H92253-501 SEAT ASSY (Interchangeable with 369B92253-503 2
in ship sets only)
-8 MS20426AD4 RIVET 1 2
-9 AN960PD04 I WASHER 2
-10 L8 T4V CABLE 2
-11 SLS4B15S PIN 1 2
-12 MS20470AD4 RIVET 1 12
-13 AN960PD04 WASHER 12
-14 Lrm~023-1-6 1 LANI~ARD 12
-15 NAB1333 C6 C07D PIN 1 12
-16 MS2 1083N4 NUT 2
AN960-416L WASHER (Interchangeable with AN960PD416L)., 3
-18 AN4- 12A BOLT 2
-19 369B92605 STANCHION ASSII, AFT (See figure 1-3 I 1
for breakdown)
-20 369B92600 1 FRAME ASSY 1 4
-21 MS2 1083N3 NUT 32
AN960-10L WASHER ~Interchangeable with 32
AN960PD10 L)
-23 NAS1203-3 BOLT 32
-24 36989260911 BRACKET, LH 8
-25 369B92609-2 1 BRACKET, RH 1 8
-26 MS21083N3 NUT 16
-27 AN960PD10L WASHER 1 16
AN960-10L WASHER (Interchangeable with 16
AN960PD10L)
-28 NAS1203-5 BOLT 16
-29 MS20426AD4 RIVET 1 3
-30 369B92611 1 SUPPORT 1
-31 3691192606 TRACK ASSY 2
-32 MS21042-3 NUT 22
-33 MS2 1042-4 NUT 4
-34 AN960PD10L I WASHER 44
AN960-10L WASHER (Interchangeable with AN960PD10L) 44
AN960-41fiL WASHER (Interchangeable with AN960PD416L),, 4
-36 AN3-5A BOLT 14
-37 AN3-6A BOLT 10
-38 369B92603-1 BRACKET, LH 1
369B92603-2 BRACKET, RH 1
-39 369B9X604-1 BRACKET, LH I 1
369B92604-2 BRACKET, RH I 1
1-4
CSP-026
UNITS USABLE
FIG.
DESCRIPTION i PER ON
INDEX PART
ASSY CODE
NO. NO.
1
1-1-40 369B92602-1 1 BRACKET, LH
P,H 1
369B92602-2 BRACKET,
LH 1
-41 369B92601-1 BRACKET,
RH 1
369B92601-2 BRACKET,
-42 NAS623-3-4 SCREW 8
AN960-10L WASHER (Interchangeable with AN960PD10L) 1 8

FITTING 2
-44 369B92250
AR
-45 V3 30-1-80-100 1 HOOK, VELCRO (Used only when 3691390123
Rotor Brake Kit is installed)
AR
-46 V330-2-100 PILE, VELCRO (Used only when 369B90123
Rotor Brake Kit is installed)
2
-47 369B92173 1 RETAINER INSTL, PASSENGER AND LITTER.
DOOR (See figure 1-4 for breakdown)
1
-48 369B90011-517 1 PROVISION, LITTER KIT (Component of
369B90011-519) (See figure 1-5 for
breakdown)
1-5
S 7
20
16
15
17
i
1~-:"
I);~ 9
~o
18
i I i~i 12
iii:\
,ij
LITTER DOOR FRAME
O LATCH COVER ASSEMBLY
jj
O LOWER SIDE COVER ASSEMBLY
o
O BUBBLE AND WINDOW ASSEMBLIES
J"
O UPPER SIDE COVER ASSEMBLY

o
O UPPER HINGE ASSEMBLY /ei

I,,
J:::
j\,
3"
UPPER COVER ASSEMB~Y
O LOWER HINGE ASSEMBLY (ROTATED)
47-248
Figure 1-2. High head room door kit
1-6
UNITS USABLE
FIG.
DESCRIPTION PER ON
INDEX PART
ASSY CODE
NO. NO.
1-2- 369B90011-511 DOOR KIT, HIGH HEAD ROOM (Component of REF

369B90011-519) (May be procured
separately) (See figure 1-1 for NHA)
1
369A9306 HANDLE, JACK
-1 i 369B92731-1 WINDOW ASSY, LH 1
369H92731-2 WINDOW ASSY, RH I 1
369890085-1 DOOR ASSY, LH I 1
369H90085-2 DOOR ASSY, RH I 1
-2 NAS1738B4 I IIIVET 0; 8
LH..........~...... 1
-3 369B92747-1 HINGE, UPPER,
RH................. 1
369H92747-2 HINGE, UPPER,
-4 NAS1738B5 I.. RIVET 4
LH................. 1
-5 369B92034-1 HINGE, LOWER,
1
369H92034-2 1.. HINGE, LOWER, RH.................
-6 MLSPB4 I RIVET 8
-7 M820470AD4 I.. RIVET 16

-8 369B92733-1 BUBBLE ASSY, LH 1
369H92733-2 1 BUBBLE ASSY, RH 1
-9 AN515C61R I.. SCREW 30

-10 AN960PD6 L I WASHER 30
LH 1
-11 369B92732-1 COVER,
RH 1
3691-192732-2 COVER, ..o
LH 1
-12 369B2038-11 COVER,
RH 1
369B2038-12 COVER,
LH 1
-13 369112038-13 COVER,
RH 1
369B2038-14 COVER, o
LH 1
-14 369B2038-15 COVER,
RH................ 1
369B2038-16 COVER,
-15 NAS43DD320 SPACER 1
AN960-10L WASHER 1
-16
C8 101F DOOR. LOCK, LH 1
-17
C8101C DOOR LOCK, RH 1
369B2048-15 LATCHING SYSTEM, LH 1

18
RH 1
369B2048-16 1 LATCHING SYSTEM,
llIn4665 1.. EXTRUSION 1
-19 00
369B92702-1 1.. DOOR STRUCTURE, LH 1

-20
DOOR STRUCTURE, RH............... 1
369H92702-2 1
1-7
Section 1
9
1 O ROTATED
oo
a
t
k c
o
~s 11 5 8~2
1
12
t./=t3
47-249
Figure 1-9. Aft stanchion

assembly
1-8

NO. NO. ASSY CODE
1-3- 369B92605 STANCHION ASSY, AFT (See figure 1-1 REF

for NHA)
-1 MS2 1083N3 NUT 24
-2 AN960-10 WASHER 24
-3 NAS1203-5 BOLT 24
-4 369H92605-19 ANGLE 3
-5 369H92605-20 ANGLE 3
-6 MS2 1083N4 NUT D
6
-7 AN960-416L I WASHER 6
-8 NAS1204-5 BOLT 4
-9 AN4 -4A BOLT 2
-10 369H92607 TRACK ASSY 2
-11 MS1083N3 NUT 2
-12 AN960-10 WASHER 2
-13 AN3- 13A BOLT 2
-14 CLH51-3 LOCK ASSY 1

-15 MS20427M3 RIVET 1 2
-16 369B92605-7 SHIM (Thickness as required) 1
-17 369B92605-9 SUPPORT 1
1-9
r:::::"I
sl
ls
U
17
J U.-
O RETAINER ROTATED IN DOOR BRACKET
i5 12
8~
9 lo
1\
*1~3
5
144~- ~_
9
15
7
6
O CLAMP ASSEMBLY WITH BRACKET
CLAMS ASSEMBLY WITH ANGLE

47-250
Figure 1-4. Passenger and litter door retainer installation
1-10
C8P-026
UNITS USABLE
FIG.
DESCRIPTION PER ON
INDEX PART
ASSY CODE
NO. NO.
369B92173 RETAINER MSTL, PASSENGER AND LITTER REF

1-4-
DOOR (May be procured separately)
AN960-10L WASHER 4
-2
-3 S10H85 PZIVNUT 4
LH 1
-4 369B92173-31 BRACKET,
RH 1
369B92173-32 BRACKET,
MS2 1042-3 NUT 8
-5
NAS1403-8 I SCREW 8
-6
AN960-10L I WASHER 8
-7
36 9B92 173-15 SPACER 8
-8 1
AN960-10 WASHER AR
-9
AN960-10L WASHER (Interchangeable with AN960-10)..... AR
TA9 C8 9SSR20 CLAMP. 4
-10
-11 MS20470AD4 RIVET 0
AR
-12 MS20670AD3 RlVET AR

LH (Not used with litter provisions 1
-13 369B92173-13 BRACKET,
installed)
RH (Not used with litter provisions 1
369B92173-14 BRACKET,
installed)
MS20426AD3 RIVET AR
-14
1
-15 369B92173-35 ANGLE, LH (Not used with litter provisions
installed)
provisions 1
3691-192173-36 ANGLE, RH (Not used with litter
installed)
TUBE ASSY 1
,16 369B92173-11
TUBE 1
-17 369B92173-5
END CAP 1
-18 369H92173-33
1-11
rp
I
i
i
"i~
ol,
rle
ie
0
0:2
O-~
m
I-,
i i I
,I
I
iIII:"
,,I
i
I
r i I
I
1I
i i:
I i
III~
i
i
7i
I
i
I
i i
II
7a
i I
i I
,il
I
i,
I~
i 2
i Il,
I
I I t
"I( L
I
1
41
1 r
L 9
"ip
I C ,,I
P
il
i
i
iI
ol~
d
IP I
ole o
o
oo
6" o a
I
l.r
II ,o
I a
i ol
47-251
Figure 1-5. Litter kit provisions
1-12
UNITS USABLE
FIG.
DESCRIPTION PER ON
INDEX PART
ASSY CODE
NO. NO.
1-5- 369B90011-517 PROVISION, LITTER I(IT (Component of....... REF

369B90011-519) (May be procured
separately) (See figure 1-1 for NHA)
-1 MS20470AD4 RIVET 18
-2 36 9B92173-13 BRACKET, LH (Also supplied with 369B92173 1
retainer installation)
369B92173-14 1 BRACKET, RH (Also supplied with 369B92173 1
retainer installation)
-3 MS20615M4 RIVET 0
8
-4 MS20470AD4 RIVET AR
-5 369B2508-205 ANGLE, LH 1
369B2508-206 ANGLE, RH 1
-6 NAS1738 B5 -3 RIVET AR
LH 1
-8 369B90011-3 ANGLE,
nH 1
369B90011-4 ANGLE,
1-13/1-14
SECTION 2
2-1. GENERAL INFORMATION locks. Four safety belts are attached to each
litter assembly.
2-2. DESCRIPTION. The litter installation
consists of two litters mounted on an aluminum 2-3, REFERENCEDATA. Informationpertain-
alloy framework in the passenger/cargo coming to helicopter structural components which
partment, and additional equipment including interface with the litter kit installation is in the
special litter doors, a door hold-open retainer, Structural Repair Manual (369D SRM). Infor-
and special seating.. Litter doors may be mation pertaining to standard helicopter equip-
equipped with flat or bubble windows that permit ment is in HMI Vol 1 and 369D-IPC.
door closure with litters installed. Door hold
open retainer equipment retains cargo doors at 2-4. LITTER. INSTALLATION
the open position when litters are installed.
Installations may contain various combinations of 2-5. REPLACEMENT OF LITTER INSTALLA-
components. The 369B90011-519 kit contains all TION COMPONENTS. See figure 1-1 and remove
litter equipment, together with the litter struc- orinstall sufficient attaching hardware for indi-
tural attachment hard points and special litter vidual component replacement or repair,
doors. The 369B90011-521 kit contains all litter
equipment and litter structural attachment hard 2-6. INSPECTION OF LITTER INSTALLATZON.
points; however, no special litter doors are pro- a. Inspect litters and supporting framework
vided. The 369)390011-511 kit contains special forcracks, corrosion, deformation, and other
litter doors and all equipment necessary to install visible damage.
the specialdoors. The 3691190011-517 kit con- b. Inspect pivot points and attacking hardware
tains the structural attachment hard points re- forwear and positive locking.
quired to mount a litter kit on the station 78.50 c. Inspect litter safety belts for worn or frayed
canted bulkhead. Extruded aluminum alloy co;;dition and loose stitching. If any doubt exists
channels (tracks) engage and support each litter as to belt strength, pull test with a 1500-pound
assembly. The forwa.rd tracks are attached to test load as specified in HMI Vol 1. Replace
the aft side of the station 78.50 canted bulkhead unserviceable belts.
and the aft tracks supported by a tubular
are
stanchion. A-frame type members, attached 2-7. REPAIR OF LITTER INSTALLATION.

with quick-release pins, form a supporting box Perform tubular weld repairs and repair damaged
between the forward and aft tracks. Teflon sheet metal according to instructions in FAA AC
runners attached to the tracks allow each litter 43.13-1, Aircraft Inspection and Repair.
to slide on the track until two automatic latching
levers each forward track snap into place.
on 2-8. LITTER DOOR INSTALLATION
A quick-release pin locks each litter on the aft
tracks. The litters may be removed from either 2-9. GENERAL. The litter door installation
side of the compartment by releasing the nearest (fig. of a door frame complete with
latching lever quick-release pin. When
and the hinges, door latching mechanism, and two alter-
the litters are removed, the support frame may nate window configurations. Either a bubble
be folded and stowed ~ainst the station 78.50 window, used with litters installed, or a standard
canted bulkhead by releasing a floor latch on the window panel may be installed on the door frame
stanchion assembly and swinging the entire as- with quick-release Camloc fasteners.
sembly upward to catch a stowaffe support
mounted on the forward track (see fig-. 2-1). 2-10. LITTERDOORFRAME, The litterdoor
The litter support framework, with the exception frame consists of a complete door frame assem-
of the upper and lower forward tracks, may be bly with automatic latching mechanism. Camloc
removed from the helicopter by pulling the eight fastener receptacles are provided in 15 locations
quick-release pins at the A-frame pivot points, that match the fasteners on either a bubble win-
The litters are hinged at the center for folding dow standard window panel. Refer to HMI
or
and are secured in the open position with hinge Vol I.for inspection and maintenance of the door
2-1
Section 2 Opt Eqpt hlanual CSP-026
frame, hinges, and automatic latching mechanism. Vol 1 for door window maintenance. Replace
See figure 2-2 for replacement of Camloc fastener Camloc fasteners and deflector as shown in
receptacles. figure 2-2.
2-11. LITTERDOOR BUBBLEWlNDOW. The 2-12. LITTER DOOR STANDARD WINDOW.

removable bubble window assembly is installed The standard window assembly is removable and
on the litter door frame when the helicopter is is used with the litter door frame when the litter
equipped with litters. The clear stretched acryl- door bubble is not installed. The clear acrylic
ic bubble is fastened to the outside of the door window is bonded in extruded plastic retainers.
frame with 15 Camloc fasteners. Two plastic The window is fastened through the edge retain-
snap vents provide for intake or exhaust of venti- ers to the outside of the door frame with 15
lating air. Clear acrylic ribs and a Geon plastic, Camloc fasteners. Two plastic snap vents pro-
airfoil-shaped deflector control airflow over the vide for intake orexhaust of ventilating air.
window surface. The ribs are bonded to the win- Refer to 369D SRM for repair of plastics and
dow bubble and the air deflector is attached with to HNII Vol 1 for inspection and maintenance
screws and barrel nuts to every other rib. Refer procedures. Replace Camloc fasteners as shown
to 369D SRM for repair of plastics and to HMI in figure 2-2.
2-2
CSP-026 Opt EgPt Mancral Section 2
UPPER AFT TRACK

ISTOWEDI
UPPER "A" FRAME ~5

CANTED STATION 78.50
STANCHION
STOWAGE SUPPORT i i// STANCHIDN
LOCK ASSEMBIY
LOWER "A" FRAME
FLOOR CHANNEL
RELEASE
j
SUPPORT
O STANCHION ASSEMBLY- FLOOR LATCH

07-252
Figure 2-1. Litter frame installation stowed position
2-3
Section 2 8pt Eqpt Manual CSP-026
CAMLOC STUD ASSEMBLY

nm,,R
DOUBLER
WINDOW
LITTER DOOR FRAME SEAL
LOCKWASHER
~a
O CAML_OC FASTENER ASSEMBLY
C
i
RETAINER
\/i
Ij
SEAL
CAMLOC FASTNER (TYPICAL)
CAMLOC RECEPTACLE ITYPICAL)
11
LITTER DOOR WINDOW
47-253-1
Figure 2-. Litter door installation (sheet 1 of 2)

2-4
O CAMLOC FASTENER ASSEMBLY-BUBBLE WINDOW
CAMLDC STUD ASSEMBLY
PLASTIC BUSHING
LITTER DOOR BUBBLE
SEAL
WASHERS
LOCKWASHER
f
a
CAMIOC FASTNER (TYPICAL)
a
ii ii
b
i
ii i
i
i
DEFLECTOR
i,
p
SNAP VENT
.:::B
SCREW AND BARREL NUT ITYPICAL)
SEAL
RIBS (TYPICALI
LITTER DOOR BUBBLE
47-253-2
Figure 2-2. Litter door installation (sheet 2 of 2)
2-5/2-6
SECTION 3
3-1. GENERAL INFORMATION 3-5. REMOVAL OF HELICOPTER EQUIPMENT
3-2. SCOPE. Procedures in this section may be 3-6. Prior to installing a litter kit, a limited
performed operators discretion. These
at the number of items must be removed from the heli-
instructions assume installation of the complete copter. Refer to HMI Vol 1 and perform the
litter kit (369B90011-519) which includes the following:
(3691190011-521), litter
litter kit without doors a. Remove crew and passenger compartment
doors only (369B90011-511), and litter provisions seats,
only (369B90011-517). The operator may install b. Remove following crew compartment trim
any one of the four kits by simply omitting those panels as required:
steps which are not applicable. Reference is (1) Centrals tunnel cover.
made in the instru.ctions to applicable data in (2) Shoulder beam panel.
HMI Vol 1 required to accomplish installation (3) Left and right bulkhead panels.
of the litter kit. (4) Left and right lower aft panels.
c. Remove following passenger compartment
3-3. REFERENCE DATA. Table 3-1 lists con- trim panels as required:
sumable materials and expendable items required (1) Forward bulkhead panel.
for installation. Items listed are recommended (2) Left and right door panels.
items of commercial nature which may be pro-
a (3) Floor carpeting and floor pan.
curedlocally. Alternate, butequivalent, items
NOTE: 389MD helicopters are not equipped
are acceptable.
with trim panels.
3-4. PREPARATION. Preparation for installa- d. Remove passenger compartment doors.
tion of the litter kit includes the following: e. For 369MD helicopters, remove passenger
a. Identify all removed components including compartme~lt ashtray.
attaching hardware and components removed to f. If helicopter is equipped with rotor brake
gain access to work areas. Protect components installation, remove passenger compartment
from damage and foreign matter until reinstalled. convenience panel.
b. Check all electrical switches for OFF g. Remove fuel cells forward vent lines.
po sition
3-7. INSTALLATION OF LITTER KIT PROVTSIONS
NOTE: Pay particular attention to BATT-
OFF-EXT switch and ensure that switch is 3-8. The litter kit provisions (369B90011-517)
in the OFF position. consist of structural attachment hard points and
Item Specification Commercial Product

No. Material No. Name/No. Manufacturer
1 Compound, MIL-S-7502 PR 1221 Product Research

Sealant Burbank, California
EP711 or Coast Pro-Seal

Pro-Seal 247 Compton, California
2 Paint and painting NOTE: For information on products, sources, colors, etc,
materials refer to HMI Vol 1.
3-1
structural reinforcement members required to fig. 3-1). Use angles (15) as template and deter-
install a litter kit on the station 78.50 mine rivet hole locations on station 78.50 bulk-
bulkhead, head. Drill rivet attach holes, 0.069- to 0.074-
a. Locate structural reinlorcement angles (8, inch diameter, using drill motor and appropriate
fig. 1-5) to forward side of station 78.50 canted drillbit, Attach angles (15) to 78.50 bulkhead
bulkhead using two existing 0.070-inch tooling using rivets (14).
holes (view B, fig. 3-1). Use angles (8) as a b. Position structural reinforcement brackets
template aiid determine rivet hole locations on (13, fig. 1-4) on forward side of station 78.50
station 78.50 canted bulkhead. Drill rivet attach canted bulkhead as shown in figure 3-1. Locate
holes, 0.069- to 0.074-inch
diameter, using: drill nine existing
rivets which must be removed prior
motor and appropriate drill bit. Attach angles (8) to installation of reinforcement brackets. Remove
to 78.50 bulkhead using rivets (6, 7). rivets using drill motor and appropriate drill bit.
b. Position structural reinforcement ~uigles (5, Use brackets (13) as template and determine rivet
fig. 1-5) on forward side of station 78.50 canted hole locations on 78.50 bulkhead. Drill rivet attach
bulkhead (view A, fig. 3-1). Locate thirteen holes, 0.069- to 0.074-inch diameter, using drill
existing rivets which must be removed prior to motor and appropriate drillbit. Attach brackets
installation of reinforcement ~ulffles. Remove (13) to 78.50 bulkhead
using rivets (11, 12).
rivets using drill motor and appropriate drill bit. c. Using drill motor and appropriate drill bit,
Use angles (5) as template and determine rivet drill eight 0.190- to 0.199-inch diameter holes
hole locations on station 78.50 bulkhead. Drill through station 78.50 canted bulkhead and struc-
rivet attach holes, 0.069- to 0.074-inch diameter, tural reinforcement angles (15) and brackets (13)
using drill motor and appropriate drill bit. Attach at locations shown in figure 3-2.
angles (5) to 78.50 bulkhead using rivets (3, 4). d_. Install the retainer assembly (16, 17, 18,
c. Position structural reinforcement brackets fig. 1-4) on station 78.50 canted bulkhead using
(2, fig. 1-5) on forward side of station 78.50 clamps (10), washers (7, 9), spacers (8), screws
canted bulkhead as shown. Locate nine existing (6), and nuts (5).
rivets which must be removed prior to installa- e. Locate brackets (4) on passenger doors in
tion of reinforcement brackets. Remove rivets such a manner as to allow tube (16) to contact
using drill motor and appropriate drill bit. Use brackets (4) when doors arein open position.
brackets (2) as template and determine rivet hole Install brackets (4) on passenger door frames
locations on station 78.50 bulkhead. Drill rivet using rivnuts (3), washers (2), and screws (1).
attach holes, 0.069- to 0.074-inch diameter,
using drill motor and appropriate drillbit. Attach 3-11. INSTALLATION IOF STANCHION SUPPORT
brackets (2) to 78. 50 bulkhead using rivets (1).
3-12. The stanchion support is a component of
3-9. INSTALLATION OF PASSENGER AND the stanchion assembly and is shipped assembled
LITTER DOOR RETAINER with the litter kit installation.
a. Remove stanchion support (17, fig. 1-3)
3-10. The passenger and litter door retainer from stanchion assembly by releasing lock
installation consists of a tubular assembly at- assembly (14).
tached to the station 18.50 canted bulkhead with b. Position stanchion support (17, fig. 1-3)
four clamps. With the passenger or litter doors over passenger compartment floor channels at
in the open position, a tube is slid out of the tubu- station 96.42 and station 102.23 as shown in
lar assembly to contact a bracket attached to the figure 3-3.
door frame and thus retain the door in the open
position. Refer to figures 3-1 and 3-2 and install NOTE: These floor channels are the third
the passenger and litter door retainer as follows: and fourth floor channels aft of the station
78.50 canted bulkhead.
NOTE: Angles (15, fig. 1-4) and brackets (13)
are to be installed only when the litter provi- c. Center stanchion support (17, fig. 1-3) on
sions kit is not installed. The following BL 0.00 and measure gap betweetl aft edge of
instructions assume angles (15)
installation of third floor channel al~d forward end of stanchion
and brackets (13); however, omit
steps a. atld support while stanchion support is firmly seated
b. if installation of the litter kit provisions over floor channels.
rpara 3-7) has be~n accomplished. d. Peel laminations from stanchion support
shim (16, fig. 1-3),as required, to obtain thick-
a. Locate doubler angles (15, fig. 1-4) to for- ness equal to gap measured in previous step.
ward side of station 78.50 canted bulkhead using Position shim on forward end of stanchion
support
two existing 0.070-inch tooling holes (view B, (17) and drill two 0.069- to 0.074-inch diameter
3-2
CSP-026 Opt EqDt Manual Section 3
CONTROLS TUNNEL 78. 50 CANTED BULKHEAD
b~g
.P REMOVE EXISTING
RIVETS 9 PLACES oaoo
NOTE:
USED WITH DOOR RETAINER
INSTALLATION ONLY WHEN INBOARD SEAT
LITTER KIT PROVISIONS ARE BELT FITTING
NOT INSTALLED.
OUTBOARD SEAT
BELT FITTING
VIEW LOOKING AFT
CONTROLS
TUNNEL
OUTBOARD
REINFORCEMENT 1 /78.50
ANGLE
EXISTING
ANGLES
TOOLING
HOLES
INBOARD
REINFORCEMENT
ANGLE
DOUBLER ANGLE ;/J

(NOTE)
a
o OUTBOARD SEAT BELT
REMOVE EXISTING
FITTING
RIVETS 13 PLACES L--~KIQ
n
O O
INBOARD STRUCTURAL OUTBOARD STRUCTURAL
REINFORCEMENTANGLE LOCATION REINFORCEMENT ANGLE LOCATION
47-254
Figure 3-1. Litter kit provisions installation
3-3
BL BL
24. 75 22. 60
CONTROLS
TUNNEL
SHOULDER
BEAM
WL 45. 36
-T-P
OUTBOARDSTRUCTURAL r--
REINFORCEMENTANGLE
INBOARD STRUCTURAL
REINFORCEMENT ANGLE
~41
1 0.186-0.189 INCH
-r REMOVE EXI STING NUTPLATE
DIAMETER BOLT
(2 PLACES)
ATTACH HOLES
11. 44 O
UPPER LITTER TRACK (12 PLACES)
ITYP)
01 O
000R RETAINER LITTER DOOR 0. 190-0. 199 INCH
BRACKET REIAINIR I OIAMETER SCRLW
0) cii~l ATTACH HOLES

(8
o----i--
PLACES)WL 34.36
-J~it
---r
Ij
I
15. 13
0.186-0.189 INCH
DIAMETER BOLT I I I I lo: 72
ATTACH HOLES
(12 PLACES)
O O
3. 58 ii
O O
WL 21. 50
LOWER L ITTER TRACK
BL
6.50
VIEW LOOKING FORWARD
47-255
Figure 3-2. Litter kit location diagram
3-4
Manua~
Section 3
CSP-026 Opt Eqpt
STA
STA
102.21.
94.42
FLOOR CHANNEL
STANCHION
SUPPORT
i. I_ .L-~-;-=-l,r___
BL
O.DO
--I-I---I---------
FWD
STANCHION
BL 2 HOLES 0. 070-0. 278 INCH

0. 00 DIAMETER IN LINE THRU
FLOOR CHANNEL TO MATCH
SUPPORT
RIVET 2 PLACES
c
I
I
I
O
t~
0.23
SHIM
47-256
Stanchion support location diagram

Figure 3-3.
3-5
holes at locations shown in figure 3-3. Counter- Also, locate existing rivets which must be re-
sink holes on outer side of shim and secure shim moved to allow installation of brackets. Remove
to stanchion support with rivets (15, fig. 1-3). track assembly.
e. Position stanchion support (17) over floor f. Remove four existing bolts from outboard
channels and center on BL 0.00. Use stanchion seat belt fitting on forward
right side of station
support as a template and determine bolt hole 78.50 canted bulkhead. Retain fitting for
locations. Drill bolt attach holes, 0.270- to installation.
0.278-inch diameter in line through two sides
of Position lower track assembly
g. (31, fig. 1-1)
each floor channel, using
drill motor and appro- with attached brackets (39, 40) on aft side of sta-
priate drillbit. Attach stanchion support (17) to tion 78.50 canted bulkhead shown in
as figure 3-2.
floor channels using bolts (18, fig~. I-i), washers
Temporarily attach right side of assembly to buik-
(17), and nuts (16). head with drift pins or bolts. Maintain alignment
and determine that end brackets (39) are identical
NOTE: Bolts (18, fig. 1-1) must be installed distance above floor. Using brackets (39, 40) as
in direction shown.
templates, mark location of bolt attach holes.
Also, locate existing rivets which must be re-
3-13. INSTALLATION OF HIGH HEAD ROOM moved to allow installation of brackets. Remove
DOOR KIT track assembly.
h. Remove existing
rivets which interfere with
3-14. The high head room door kit (fig. 1-2) con- installation of brackets (38, 39, 40, 41,
fig. 1-1)
sists of two passenger compartment door frames and replace with flush rivets.
and two types of windows for each door. The door i.
Using drill motor and appropriate drill bit,
frames are complete with installed
hinges, latch- drilleighteen to twenty-four 0. 186- to O. 189-inch
ing systems, and door locks. Quick-release diameter holes, as required, through station 78.50
fasteners are used to attach either
a flat window canted bulkhead and structural
angles (5, 8,
bubble window to the door frame. Install
or a
fig. 1-5) at locations shown in figure 3-2.
doors as follows:
i. Install upper and lower track assemblies
Install two doors in accordance with instruc-
a.
(31, fig. 1-1) and secure brackets (38, 39, 40, 41)
tions contained in HMI Vol 1. to 78.50 canted bulkhead with bolts
b, Position window of desired
(36, 37),
configuration on washers (34, 35), and nuts (32, 33) as shown in
door and secure in place with captive quick- figure 1-1. Verify that outboard seat belt
fitting,
release fasteners. removed in step f, is installed on forward right
side of canted bulkhead.
3-15. INSTALLATION OF LITTER KIT k. Secure frame assemblies (20, fig. 1-1) and
attach stanchion assembly (19) to track assemblies
3-16. The litter kit consists of two
litters, litter (31) using pins (15).
support framework and attaching hardware, two i. Attach and lock stanchion assembly
attendant seats, seat belts, and shoulder
(19,
straps, fig. 1-1) to stanchion support fitting (44).
Refer to figure 1-1 and install litter kit follows:
as m. Install seat assemblies (7, fig. i-i),
a. If
optional rotor brake kit is installed,
an
shoulder straps(6), and seat belts (5) as shown
bond Velcro pile (46) to station 78.50 canted bulk- in figure 3-4.
head and~bond Velcro hook (45)
to convenience n. Slide litter assemblies (3, fig. 1-1) into
panel in such
way that Velcro strips may be used
a tracks of stanchion assembly (19) and track
to secure convenience panel to canted bulkhead,
assemblies (31). Ensure that track latches
b, Secure shoulder strap fittings (44) to aft
secure litter in place and install pins (11).
bulkhead using (42),
screws washers (43), and o.Install VNE card assembly (1, fig. 1-1).
existing nutplates at WL 39 (approximately). P Apply stenciled NO SMOKING words in 0. 5-
c. Remove pins (15) and separate track inch high letters, using black or red
paint, to aft
assemblies (31) from assembled litter frame side of station 78.50 canted bulkhead in
accordance
assembly (20). with table 3-1. Center letters on BL 0.00
d. Refer to figure 3-2 and remove two approx-
existing imately 2 inches above upper litter.
nutplates from forward side of station 78.50
canted bulkhead.
3-17. INSTALLATION OF HELICOPTER
Position upper track
e.
assembly (31, fig. 1-1) EQUIPMENT
with attached brackets (38, 41) on aft side of sta-
tion 78.50 canted bulkhead as shown in
figure 3-2. 3-18. After installation of litter
kit, a limited
Maintain alignment with drift pins or
temporarily number of items must be replaced in the
helicop-
installed bolts. Using brackets (38, 41, fig. 1-1) ter. Refer to HMI Vol 1 and perform the
as templates, mark location of bolt attach holes.
following:
3-6
CSP-026 Opt Eqpt Rilanual Section 3
L/
Q
LITTER KIT
SEATS AND BELTS
SHOULDER STRAP
SEAT BELT
47-257
Figure 3-4. Attendant seats
3-7
a. Install crew compartment seats. d. If helicopter is equipped with rotor brake

11 Install following crew compartment trim installation, install passenger compartment
panels as required: convenience panel.
(1) Controls tunnel cover.
(2) Shoulder beam panel.

(3) Left andright bulkhead panels. 3-19. WEIGHT AND BALANCE DATA
(4) Left andright lower aft panels.
c. Install following passenger trim panels,
3-20. Weight and balance data resulting from
as required:
installation of the various litter kits are listed
(1) Forward bulkhead panel.
in table 3-2. After installation of any litter kit
(2) Left and right door panels.
configuration called out in table 3-2, incorporate
NOTE: 369MD helicopters are not equipped changes in helicopter weight and balance records
with trim panels, as instructed in HMI Vol 2.
Weight Arm Moment

Item (pounds) (inches) tin. -lb/100)
-511 Door Kit
Standard windows
Added 23.7 100.5 24

Removed
Changed 23.7 100.5 24
Bubble windows
Added 25.9 96.3 25

Removed (standard windows) 8.3 98.7 8
Cha~iged 17.6 95.2 17
-517 Provisions Kit
Provisions only
Added 1.4 84.1 1
Removed
Cha~iged 1.4 84,1 1
-519 Litter Kit
Complete with doors, bubble windows

Added 102.0 97.3 99
Renloved (standard cargo doors) 21.6 100.0 22
Changed 80.4 96.6 77
Complete with doors, standard windows
Added 84.4 97.7 82

Removed (st;uldard cargo doors) 21.6 100.0 22
Changed 62.8 97.0 60
-521 Litter Kit
Complete without doors
Added 60.7 96.7 58

Removed
Cha~lged 60.7 96.7 58
3-8
CSP
029

and
Mainfenance Instructions
with Initial Instalkafion Instruetions
FOR
PASSENGER/CARGO HOIST SYSTEM
Part No. 3691190070-521

and 3691190070-522
E~ Hushes Helicoptern
COD041078 Issued 1 May 1978

NI FG,
INTRO
CSP-029
Opt Eqpt Manual
INSIII LATLII CHANGED rAGES, DtLIIOY IVrEIIEDED IAGES.

LIST OF EFFEC~IWE PAGIS THE L~TLAISK INDICAtCO CABEL CHANOEO. *ODEO. OR DELETED BV THE CURRENT CHANGE.
Title Original F-l,,., i...,........., Original

Athru B Original F-2 Blank, Original
CBlank Original 1-1 thrul-l0 Original
i Original 211 thru 2-12 Original
ii Blank Original 3-1 thru 3-10 Original
revisions.
Hughes Helicopters
Attention: J. J.
Dillon, Commercial Service Publications
2/T7B
Originator
Address
Figure Number(s)
Remarks/Recommendations
B/C
RECOBD OF REVISIONS
CSP-029
MFG REV
ATP RN INSERT DATE REV REMOVE

RE/ NO
TABLE OF CONTENTS
Section Page
FOREWORD F-r

of this Manual F-l
Combined Optional
Equipment.......... F-l
F17, Organization of
Contents F-l
F-9. Use of This Manual..... F-l
Related Publications.... F-l
F-L3. Literature Changes
and Revisions F-1.
1 ILLUSTRATED PARTS LIST I-1
I-i. Scope and Contents

1-3. Group Assembly
Parts List
2-1. General Information.... 2-1

2-8. Troubleshooting. 2-3
2-10. Operational Check 2-3
1\ 2-12. Removal of Hoist
Assembly 2-4
TABLE OF CONTENTS
Section Page
2 MAINTE~QANCE INSTRUCTIONS
(CONT)
2-14. Inspection of Hoist
Equipment.......... 2-4
Winch Components 2-4
2-20. Installation of
Hoist Assembly 2-8
Hoisting Operations 2-8
2-24. Plrfng and Schematic
Diagrams 2-9
3 INSTALLATION INSTRUCT~ONS.. 3-1

3-5. Removal of Equipment... 3-2
3-7. Modification..... 3-2
3-9. Installation of Electrical
Equipment (Commercial
Helicopters)..... 3-4
3-11. Installation of Electrfcal
Equipment (Military
Helicopters) 3-5
3-13. Assembly of Hoist 3-6
3-15. Installation of Passenger/
Cargo Door Retainer 3-6
3-17. Installation of Hoist 3-6
3-19. Installation of Equipment. 3-8
FOREWORD
F-l. PURPOSE AND CONTENT OF THIS section is organized to provide comprehensive

MANUAL. coverage of entire systems, major equipment
F-2. This manual supplements information con- similar or associated. (Procedures for each of
tained in HMI Voll and 369D IPC, and con- these are presented in sequence as defined in
tains instructions for initial installation and section 1, HMI Vol 1.)
continuing maintenance for the passenger/cargo
hoist kit assemblies. Weight and balance data is F-9. USE OF THIS MANUAL.
included. This manual also contains parts lists
for procuring replacement parts for the passenger/ F-10. This manual is for use by operators of the
cargo hoist kit assemblies. Model 369D helicopter equipped with a passenger/
cargo hoist kit. Although this manual is a separ-
F-3. APPLICABILITY. ate publication, it should be kept with HMI Vol 1,
HMI Vol 2, 369D IPC and other handbooks
F-4. The passenger/cargo hoist kits are appli- listed in section i, HMI Vol 1 that form the
cable for use on any Hughes 500D or 500MD primary information file for the helicopter.
(Model 369D) helicopter.
OPTIONAL EQUIPMENT.
F-6. For compatibility information on which of HMI Vol 1 and 3691) IPC as required to
optional equipment may or may not be used in accomplish instructions contained herein.
combination at the same time, refer to section 21,
HMI- Vol 1.

F-8. The contents of this manual are grouped into manual are made as defined in section i,
sections as outlined in the Table of Contents. Each HMI Vol 1.
F-1/F-2
.SECTION 1
ILLUSTRATED PA#TS LIST
1-2. This illustrated parts list provides, by 1-6. An isometric illustration is provided and
means of text (parts lists) and companion illustra- includes a combined parts list, with variations
tions, a complete parts definition of the noted, for both 369H90070-52 and 369B90070-522
369H90070-521 (military configuration) and passenger/cargo hoist kits. The illustrations are
369B90070-522 (commercial configuration) exploded to the extent necessary to show the parts
passenger/cargo hoist kits, manufactured by relationship for complete passenger/cargo hoist
Hughes Helicopters, Culver City, California. kits.
NOTE: The illustrated parts list is organized 1-7. USABLE ON CODE.

and presented in the same manner as the 369D
Series Illustrated Parts List (369D IPC). (For 1-8. The USABLE ON CODE column located at
information on use, refer to the 369D IPC.) the right-hand side of the Group Assembly Parts
List pages indicates the effectivity of parts by air-
1-3. GROUP ASSEMBLY PARTS LIST. craft serialnumber. In many cases two different
parts are listed, one representing the original
1-4. The
parts lists furnish information for pro- installation and another representing an improved
curing replacement parts for the passenger/cargo replacement item. Alphabetic codes are used to
hoist kits, and shall not be used for any other indicate the aircraft serial number applications
purpose. (For information or procurement of of a given part. When no USABLE ON CODE is
replacement parts, refer to 369D IPC.) listed, items are understood to have full effectivity.
1-1
Section 1
HOIST
PWR CTR
1Ati
32 31
COMMERCIAL SWITCH AND

O CIRCUIT BREAKER PANEL
QIIIILITAAY CIRCUIT BREAKER PANELS
(j
Holil CTR
FLD
3690294566 PANEL~*
32 31
~II
I HOIST
CTR PWR
,2
1
369H92143 PANEL
~HOIST CABLE ANITCHAFINGBAR
47-261-11\
Figure 1-i. Hoist kit components (sheet 1 of 3)

1-2
22 O HOISTSUPPORTANDATTACHMENTS
(ROTATED)
23
17
16 27 ~24
15 18
i i: II
i i
13
26 i i i
25 i i
21
29
I
ii
i
1~iiIio 4~
O CABLE ANTI-SNAG PROVISION
(ROTATEDI
r;
i
3C:
36 i i:i i
I
/jI,
I
1, i i
~ZI
i\.I */7 9
II
47-261-2A
Figure 1-1. Hoist kit components (sheet 2 of 3)
1-3
sectibn 1
(3 PENOANT CONTROL CONNECTOR
~i--- 33
t -j
45t
17~
t(
;1
t
II
i
3ii
./""7~-
-i! I
DA OHOIST CONNECTOR
t
r,-~,
-/IiI O
31----L;
47-261-34
Figure 1-1. Hoist kit components (sheet 3 of 3)

1:4

NO. I NO. ASSY CODE
1-1- 3691190070-522 HOIST KIT (Commercial configuration) REF

36 9B90070-521 HOIST KIT (Military configuration) REF
-1 MS2 1043-08 1 NUT 2
-3 NASG 02 8 1 SCREW 2
-4 369D292551-3 1 CHAFING BAR ASSY (LH DOOR SILL) 1
(Component of 369B90070-521)
36 9D29255 1-4 CHAFING BAR ASSY (RH DOOR SILL) 1
(Component of 369B90070-522)
-6 AN96 0PD416 I WASHER 2
-7 369D292553 CLIP. 2
NA.S603-8 SCREW (Component369B90070-521)
of 3
36 9D2925 56 CHAFING BAR ASSY (LH LANDING 1
GEAR SKID) (Component of 369B90070-521)
-8 S2528KB80 I RIVNUT 1 2
-9 MLS100-M4-2 RIVET 2
-10 3691192023 1 HARNESS, BODY 1

-11 3691192173 1 RETAINERINSTL, PA.SSENGER/CARGO 1
DOOR (See figure 1-2 for breakdown)
-12 369B92012 1 TUBE ASSY (Component of 369B90070-522) 1
3691192011 1 TUBE ASSY (Component of 369B90070-521) 1
-13 SLC 3R08 PIN, SAFETY. 1
-14 SLC 4R09 PIN, SAFETY....................... 2
-15 MS24665-132 1 PIN, COTTER I 1
-16 AN960C10L I WASHER 1
-17 MS20392-2C21 I PIN, STRAIGHT BEARING 1
-18 369B92006121 LINK ASSY, RH (Component of 369B90070-522) 1
369B92006-11 1 LINK ASSY, LH (Component of 369B90070-521) 1
-19 MS21044N4 I NUT 4
-20 AN960D416 I WASHER 4
-21 NAS1304-4 BOLT 4
-22 369B92563-501 HOIST ASYY (See figure 1-3 for breakdown)... 1
-23 NAS623-3-5 1 SCREW 7
-24 AN9 60C10L I WASHER 7
AN960C10 ADJUSTMENT 3
-25 WASHER,
1
-26 469B92004-12 1 FITTING, AFT, RH(Componentof
3691190070-522)
1
3691192161-2 FITTING, AFT, RH(Interchangeable
with 369H92004-12)
1
3691192004-11 1 FITTING, AFT, LH(Componentof
369H90070-521)
1
3691192161-1 FITTING, AFT, LH(Interchangeable
with 3691192004-11)
1
-27 369H92005-12 1 FITTING, UPPER, RH(Componentof
369B90070-522)
1
369B92506-2 1 FITTING, UPPER, RH (Interchangeable
with 369B92005-12)
1
369B92005-11 FITTING, UPPER, LH(Componentof
369B90070-521)
1
3691192506-1 1 FITTING, UPPER, LH (Interchangeable
with 369B92005-11)
NAS623-3-6 I SCREW 3
-28
AN9 60C 10L I WASHER 3
-29
1-5

NO. NO. ASSY CODE
1-1-30 369B92162-2 FITTING, FWD, RH(Componentof 1

3891190070-522)
3691192167-2 FITTING, FWD, LH(Interchangeable 1
with 369B92162-2)
369B92162-1 1 FITTING, FWD, LH (Component of 1
369B90070-521)
3691192167-1 FITTING, FWD, LH(Interchangeable I 1
with 369B92162-1)
-31 2TC13-7-1/2 CIRCUIT BREAKER (CB601 or CB134) 1
-32 MS25036-40 CIRCUIT BREAKER (CB600 or CB133) 1
3691190070-131 HARNESS ASSY, ELECTRICAL 1
-33 NAS1291-C04M I.. NUT............................ 1 4
-34 AN960C4L I.. WASHER 1 4
-35 MS51957-15 I.. SCREW 1 4
-36 MS3101E16S-1S RECEPTACLE (XJ2) 1
-37 MS3181-4 CAP, PROTECTIVE I 1
-38 3691190070-69 1.. WASHER 1
-39 PT07C14-8S I.. RECEPTACLE (528) 1
-40 MS21043-08 NUT 2
-41 AN9 60PD8 L WASHER 8
-42 NAS671-C8 NUT 2
-43 NAS1096-2-10 I SCREW 2
-44 NAS623-3-8 1 SCREW, PENDANT STOWAGE 1
-46 NAS43DD1- 16 SPACER 1
-47 369B90129-505 GRIP, CYCLIC STICK (Component of I 1
3691190070-522) (Refer to applicable
Opt Eqpt Manual)
1-6
19 2
b.
is
II
:j
u. B~S\
u.
\i
e I?!
\I /%o-,
\G.
O
RIGHT 000R BRACKET
(ROTATED)
/15
Cb 5
/B
5
B i
B
7\ J
lo
~p Is
a
~3
9 -t 12
1l
RIGHT INBOARD O
TUBE CLAMP RIGHT OUTBOARD
TUBE CLAMP
47-241
Figure 1-2. Passenger/cargo door retainer installation
1-7
FIG. I UNITS USABLE

NO. NO. ASSY CODE
1-2- 3691192173 RETAINER INSTL, PASSENGER/CARGO DOOR I REF

-1 NAS1403-2 SCREW Z
-3 S10H85 RIVNUT I Z
-4 369B92173-42 1 BRACKETASSY, RH,,,,,,,,,,,,,,,,. i 1
369B92173-41 1 BRACKETASSY, LH,,,,,,,,,,,,,,,,. I 1
-5 MS21042-3 NUT 8
-7 AN9 60 -10L WASHER 8
-8 369H92173-15 SPACER 1 8
-9 AN960-10 I WASHER, ADJUSTMENT AR
AN960-10L I WASHER (Interchangeable with AN960c10) AR
-10 TA9C89SSR20 CLAMP 4
-11 MS20470AD4 I RIVET I AR
-12 MS20470AD3 I RIVET I AR
-13 369H92173-14 1 BRACKET., RH,,,,,,,,,,,,, 1
369 H92173 -1 3 BRACKET, LH 1
-14 MS20426AD3 I RIVET........,................,., I AR
-15 NAS1738B5-3 RIVET...........................,, AR
-16 369 H921 73 -36 ANGLE, RH I 1
369 H921 73 -3 5 ANGLE, LH I 1
-17 369 H921 73-1 1 I TUBE; ASSY 1
-18 369 H921 73 5 1 TUBE 1
-19 369B921 73-33 ENDCAP I 1
1-8
nl;
~HOIST SYSTEM WINCH, ATTACH BRACKETS,

AND HOOK STOWAGE HANGER ASSEMBLY
(ROTArEDI
65\\
CONTROL PENDANT
CAB~CUTTER
O SWITCH ACCESS DOOR ASSEMBLY
11
r 12
7 1~
~I
2
d
17
10
11
15 ~r 1
47-240
Figure 1-3. Hoist assembly
1-9
Section 1 Opt E,pt Manual CSPr029
FIG. UNITS USABLE

NO. I NO. ASSY CODe
1-3- 36 9119256 3- 501 (See figure 1-1 for NHA)

HOIST ASSY REF
-1 PT06 P14- 8P I CONNECTOR (P28) 1
-2 369 H9257 5-1 BRACKET, FWD(Replacesbracket 1
provided with hoist installed with

existing hardware)
-3 1 369B92575-2 BRACKET, AFT (Replaces bracket:.;...... 1
provided with hoist installed with
existing hardware)
-4 AN9 60C 6 WASHER 3
-5 AN935-6L I LOCKWASHER 3
-6 NASGO1-7 I SCREW 3
-7 369 H9 21 70 1 HANGER 1
-8 BL-7520-1 I HOOK ASSY I 1
-9 BL-16600-12 HOIST(WINCH) i 1
BL-7811 I CABLE CUTTER 1
369B92563-41 PENDANT ASSY 1
-10 BL-8810-1 I.. PENDANT I 1
-11 MS21042-04 NUT I 1
-12 AN9 60C L4 I WASHER 1 2
-13 AN515(=4-5 I.. SCREW I 1
369 H92 563 -31 HINGE ASSY 1

-14 369B92563-7 PZN 1
-15 369 H92 563 -9 1 SPRING I 1
-Is 369 H92 563-5 SUPPORT I 1
-17 369H92563-3 1.,, COVER 1-
1-10
SECTION 2
2-1. GENERAL INFORMA.TION. brackets used to accommodate installation of

are
the winch the support tube. The winch incor-
on
2-2. DESCRZPTION, The passenger/cargo hoist porates a disc-type brake, housed on the end of
kit assembly consists of an electrically operated the hoist drum, which consists of spring-loaded
winch mounted on a support tube, a hdist opera- friction plates and an actuating solenoid. The
tors safety harness, a passenger door (hold- solenoid is energized to release the brake at the
open) retainer assembly, a passenger door sill same time the motor is energized. Once the con-
antichafing bar assembly, a control pendant, and trol pendant switch is released to the off position,
associated electrical equipment. The hoist pro- the brake solenoid is deenergized and the brake
vides a means for
lifting and lowering personnel sets, preventing any possibility of uncontrolled
or objects weighing up to 300 pounds. The hoist cable payout. Cable up (full-in) and down (full-
system employes lightweight, readily attachable out) limit switches are incorporated in the winch
and detachable exterior mounted equipment with- brake system. When either limit switch is in the
out using passenger or cargo space in the heli- closed position, the brake solenoid is energized,
copter. For safety purposes, a guillotine-type releasing the brake discs and allowing the winch
cable cutting device is incorporated in the hoist drum to rotate. Conversely, when either limit
winch assembly. Figure 2-1 illustratesthe 500D switch is in the open position, the brake solenoid
commercial configuration hoist installed on the is deenergized and the winch brake automatically
right side of the helicopter. The 500MD mili- sets and stops the winch.
tary configuration is identical
except that the
hoist is installed on the opposite (left) side of the 2-4. The passenger/cargo door retainer assem-
helicopter. The hoist function is identical when bly consists of a tubular

housing attached with
operated from either side of the helicopter. A four clamps securing the housing horizontally
cyclic stick grip kit must be used on the commer- across the canted bulkhead in the passenger/cargo
cial configuration. compartment. With the passenger/cargo door in
full open position, a smaller tube stowed inside
NOTE: When the hoist kit is installed on com- the tubular housing, extends in a telescoping effect
mercial helicopters equipped with emergency and engages a bracket located on the outboard
floats, the floats must be in a stowed condition frame of the door, thus retaining the door in an
during hoisting operations. Emergency floats open position. The telescoping tube can be used
must be removed from military configurations i" either end of the tubular housing to hold the
before conducting hoisting operations. left or right passenger/cargo door open as
required.
2-3. The weatherproof winch consists of a 28- 2-5. An

antichafing bar, installed just below the
vde motor that drives a cable drum to which a passenger/cargo door sill, prevents the hoist
IlO-foot stainless steel cable with a swivel hook cable from cutting the door frame during hoisting
is attached. The winch is equipped with an auto- operations. A hoist operators safety harness,
matic brake system; up (full-in) and down (full- provided with the hoist kit, is connected to the
out) limit stop switches; and an explosive, elec- seat belt anchor fitting on the opposite side of the
trically activated guillotine-type cable cutter for passenger/cargo compartment from which the
cutting the cable in an emergency. The hoist hoist is installed.
assembly is mounted on a support tube attached
with quick-release pins to three fittings located 2-6. The hoist system electrical equipment con-
on the exterior of the fuselage on either side and sists of a hand-held electrical pendant control for
above the passenger/cargo door. The support use in the passenger/cargo or pilots compart-
tube positions the winch to allow raising and ments to operate the winch, an emergency cable
lowering the cable between the side of the fuselage cutter switch on the pilots cyclic stick, circuit
and landing gear skid. Two modified mounting breaker equipment, and associated electrical
2-1
WINCH
CYCLIC STICK
GRIP KIT
SUPPORT
DOOR RETAINER
TUBE
SAFEP/ HARNESS
ANTI-CHAFING
BAR
O CONTROL PENDANT
O WINCH CONTROL
SWITCH
UP
WARNING
HOIST CABLE
ITCH
OER COVER
CABLE CUTTER
SWITCH
47-268A
Figure 2-1. Hoist system components
2-2
wiring. The pendant control contains a three- a. Open applicable passenger/cargo door;
position switch, spring loaded to the off position, extend door retainer tube to hold door in lull open
for raising and lowering the swivelhook, and a position.
guarded switch for cutting the cable at the winch
inan emergency. The pilots cyclic stick cable CAUTION: Avoid inadvertent operation of
cutter switch allows the pilot to cut the hoist cable cutter. Make certain cable cutter
cable independent of the pendant control. (Refer switches are not actuated when hoist system
to applicable Opt Eqpt Manual. The circuit circuits are energized.
breakers are mounted on the lower switch and
circuit breaker panel (commercial configuration)
b. Energize helicopter electrical system; checlr
or on the circuit breaker panel located aft of the
that both HOIST PWR (power) and CBL CTR (cable
pilots collective stick (military configuration). cutter) circuit breakers are in closed position
The cable cutter circuits are independently pro- (see figure 1-1).
tected by a separate lower amperage circuit
c. Using hoist system control pendant (fiF;.
breaker located adjacent to the hoist power circuit
2-r), exercise hoist winch by paying out 3 to 4
breaker. Electricalwiring, plugs, receptacles, feet of cable under approximately 15 pounds ten-
and terminals interconnect the various electrical
sion; pull cable straight down to avoid cable rub-
components. bing on cable bellmouth. Reverse control and
reel cable in. Check that cable winds on winch
2-7. REFERENCE DATA. Refer to section 20, drum evenly and that winch operation is smooth
HMI Vol i, for interfacing schematics and wir- and consistent. Check that winch stops automatic:-
ing diagrams. Differences in commercial and ally when top of swivel hook rubber bumper pushes
military hoist installations and electrical cir- against winch bumper pad.
cuitry described in subsequent text and illus-
are
d. Provide 300-pound weight to test hoist lift-
trations. Refer to manufacturers publications
ing capability.
(table 2-2, HMT Vol 1 (BL-16600 Series 300-Lb e. With helicopter hovering approxinlately 100
Capacity Hoist Operating Instructions Hoist feet above test weight, lower hoist hook between
Winch Assembly, Breeze Corporation, Inc)) for
fuselage and landing gear skid. Continue lower-
additional hoist, hook, cable, and parts
ing hook until hook can be connected to test weight.
information, f. Gradually maneuver helicopter to remove
cable slack and to center hoist over test weight.
2-8. TROUBLESHOOTING.
g. Slowly elevate helicopter to raise test
weight approximately 20 feet from ground.
2-9. Use information in table 2-1 for trouble-
h. Using pendant control, payout full usable
shooting the hoist system length of cable; check that hoist down limit switc~z
stops winch with three turns of cable on winch
2-10. OPERATIONAL CHECK. drum. If required, adjust position at which down
limit switch activates. Refer to manufacturers
2-11. Thefollowing procedure is used to verify publications (table 2-2, HXIII Vol 1).
the capability of the hoist system to function cor-
i. Reverse pendant control: lift test uleiRht to
rectly. The procedure should be performed any within approximately 10 feet of helicopter skid.
time a malfunction is suspected, and prior to
Check that hoist operates smoothly throufih-
normal use after repair.
out hoisting and lowering operations.
WARNING: Remove protective electrical NOTE: Cable retraction rate should be ap-
jumper wire (fig. 2-2) from cable cutter proximately 55 to 60 feet per minute. The
whenever winch is installed on helicopter. full usable cable length should unwind in ap-
Jumper wire will prevent operation of cable proximately 95 seconds and rewind in approx-
cutter in an in-flight emergency. imately 103 seconds.
Table 2-1. Troubleshooting hoist
Winch will not raise or lower Tripped circuit breaker. Reset circuit breaker.
cable.
Defective pendant control. Repair pendant control.
Defective winch assembly. Repair winch assembly.
Improper lower cable travel Down (full-out) limit switch Reset lowfr lilTlit adjustment.
limit. out of adjustment.
2-3
k. Lower
helicopter and remove hoist hook WARNING: Use heavy leather gloves to pro-
from test weight; raise hoist hook and check that teet hands from injury due to broken cable
hoist winch automatically stops when top of swivel strands,
hook rubber bumper pushes up against hoist bump-
er pad. CAUTION: Keep cable clean. Provide a clean
area to coil cable during inspection. Dirt and
NOTE: Up limit switch should actuate before oilgrime will create an abrasive wear on
excessive cable pressure is applied to verti- cable and winch components.
cally compress bumper pad (see figure 2-2).
b. Inspect cable for fraying, corrosion, broken
i. Land helicopter; deenergize electrical strands, and security of attachment to winch drum
system. and cable ball swivel hook attachment. General
m. Stow pendant control. criteria for cable replacement are as follows:
n. Stow door retainer tube; close passenger/ (1) Any single broken strand (cluster of 7
cargo door. individualwires) requires cable replacement.
(2) Both ends of individual broken wires
2-12. REMOVAL OF HOIST ASSEMBLY. should be tucked into cable to prevent fouling when
cable travels through cable guides and nonfouling
2-13. To remove the hoist assembly, proceed as mechanisms. Breaks of individual wires are
follows: allowable, unless the number is excessive as de-
a. Check that cable is fully retracted on winch fined in (3) below.
drum. (3) Generally, one individual broken wire
Check that BATTERY switch is in OFF (two ends) for each foot of cable is permissible,
position. up to a total of 20 individual wire breaks for each
c. Install safety jumper wire on cable cutter 100-foot length of cable. A greater number of
electrical terminals (see figure 2-2). breaks requires cable replacement.
c. Refer to winch manufacturers operating
CAUTION: Protective jumper wire should re- instructions (table 2-2, HMI Vol 1) for addition-
main on cable cutter electrical terminals until al information.
winch is reinstalled for use.
2-16. REPLACEMENT OF WINCH COMPONENTS.

d. Disconnect winch electrical plug (1, fig.~l-3)
from receptacle on fuselage; install protective cap 2-17. REPLACEMENT OF WINCH CABLE. Re-
on receptacle.
Support winch; remove three quick-discon-
e, if cable is damaged, worn excessively, or cable
nectsafety pins (13, 14, fig. 1-1) securing winch cutter has been fired (see paragraph 2-14 for in-
support tube (12) to fittings on fuselage, spection requirements and for cable replacement
f. Remove winch (22) and support tube (10) criteria).
from fuselage. Install hoist and
a. support on helicopter (refer
g, Remove cotter pin (15), washer (16), and to paragraph 2-20).
bearing pin (17) securing link assembly (18) to
winch support tube (12).
CAUTION: When electrical power is present,
make certain cable cutter electrical circuits
NOTE: If support tube fittings (26, 27, 30)
to be removed from
remain deenergized to eliminate the possi-
are fuselage, make cer-
tain nylon screws (12, table 3-1) are installed bility of inadvertent actuation of cable cutter.
in attachment holes. To avoid possibility of cutting cable, install

jumper wire between cable cutter electrical
terminals (see figure 2-2).
h. Remove bolts (21, fig, 1-1) securing winch
(22~ to support tube brackets.
b. Connect external electrical power source to
2-14. INSPECTION OF HOIST E&UIPMENT. helicopter.
c. Place BATTERY switch in EXT position.
2-15. General inspection procedure for the hoist
system is as follows:
NOTE: An external power source should be
a. Inspect components for security of attach-
connected to the helicopter to prevent exces-
ment, damage, deformation, cracks, and exces-
sive battery discharge. Hoist uses up to 40
sive wear.
amperes electrical current during operation.
WARNING: Human life might depend on cable
condition. Inspect full length of cable care- d. Using hoist pendant control (fig. 2-1), reel
fully and thoroughly, off all cable from winch drum as follows:
2-4
WINCH
HOIST SUPPORT
TUBE
OI
DOUBLE HELICAL SCREW
SHAFT1~ CABLEGUIDEASSEMBLY
(TIGHTEN NUT TO TORQUE OF

IDLER GUIDE ROLLER 70-100 INCHIPOUNDS)
PRESSURE ROLLER
~TJ
TRACTION ROLLER
ALLEN HIAD SET SCREW
FULL-IN IUP) INDENT

LIMIT SWITCH
CABLE CUTTER
(GUILLOTI
BELLMOUTH
PROTECTIVE Y I I RING
ELECTRICAL
JUMPER
(SEE
BEER BUMPER PAD
WARNING: REMOVE JUMPER WIRE

1/8 IN, DIAMETER CABLE AFTER SYSTEM INSTALLATION OR
MAINTENANCE (REFER TO TEXT).
ELECTRICAL
GROUN D WI RE WIRING
BLUE,
OR WHITEIBLUE)(WHITE, O CAUTION: CONNECT POSITIVE WIRE
ONLY (BLACK,GREEN, OR WHITEIGREEN)
t~
POSITIVE WIRE (BLACK, CABLECUTTER
TO POSITIVE POST OF CABLE CUTTER.
GREEN, OR WHITEIGREEN) REPLACEMENT
ISEE CAUTION)
47-274-1
Figure 2-2. Winch cable, cable cutter, and swivel hook replacement (sheet 1 of 2)
2-5
AUBBERBUMPER
KEYWAY
CABLE
p
SOCKET
HOOK HOUSING
\I\
SWIVEL HOOK
SWAGED BALL
END FITTING
SAFTEY KEEPER
O
CABLE TO HOOK
ATTACHMENT
ROLLER WHEELTOP COVER
FULL-OUT (DOWN
FIRST DRUM G LIMIT SWITCH
(NOTE 1)
CABLE EN
ALIEN HEAD SETSCREW

NUT, WASHER
(4 PLACES) (NOTE 1)
HOOK HANGER (NOTE 2)
DRUM
1
CABLE WINDING
j~ i
IONDRUM)
CABLE D
FLANGE
CABLE GUIDE
NOTES: ASSEMBLY
i. EXCESSIVE TIGHTENING MAY AFFECT ~\DRUM CABLE END

FULL-OUT SWITCH SETTING. ,s, ANCHOR HOLE
2. USED FOR HOOK STOWAGE
CABLE TO DRUM
ATTACHMENT
47-274-2
Figure 2-2. Winch cable, cable cutter, and swivel hook replacement (sheet 2 of 2)
2-6
NOTE: Two persons can facilitate cable re- (2) Make certain that cable guide assembly
moval; oneperson to operate winch and a is centered and aligned with first groove on double
second person to handle and coil cable. helical screw shaft. Facing cable guide mecha-
nism, check that guide will travel from right to
(1) Operate winch and start reeling cable left when winding cable on drum.
off winch drum. (3) Secure cable to drum by loosening set-
screw and inserting cable end into drum cable
CAUTION: To prevent bellmouth wear, cable anchor hole until cable end bottoms (approximately
should not be pulled against side of bellmouth 3/8 inch); tighten setscrew.
on cable guide. (4) Check that replacement cable is posi-
tioned in first drum groove at right when facing:
(2) As cable unwinds, maintain straight cable guide mechanism.
downward tension (approximately 15 pounds); lay j. Operate hoist and wind replacement cable
or coil cable in a clean clear area. Position on winch as follows:
cable so that cable will not kink or tangle to facili- (1) Deactivate down limit switch by manually
tate rewinding. raising teflon roller wheel at top right rear of
(3)Continue unwinding cable until down winch drum; use control pendant to wind replace-
(full-out) (fig. 2-2) activates (opens)
limit switch ment cable on winch. Release the down limit
and allows brake to engage, thus stopping cable switch after three turns of cable are on drum.
payout. (2) Maintain sufficient tension (approxi-
mately 15 pounds) on cable while winding cable on
NOTE: Three turns of cable will remain on drum; check that straight, smooth,
cable winds
winch drum when down limit switch opens, and snug, without kinking against cable windinffs
on drum. Avoid cable rubbing on side of bell-
(4) Remove winch cable drum cover, mouth during cable winding.
(5) Manually raise roller wheel, at top (3) Continue winding operation until entire
right of winch drum, to close the down limit
rear cable is wound on drum; check that winch stops
switch (release brake) and allow remaining cable automatically when top of swivel hook pushes
to be reeled off cable drum. against winch rubber bumper pad. (Bumper pad
(6) Using controlpendant, finish unwinding upward movement actuates (opens) full-in (up)
cable. Stop winch when cable is fully unwound limit switch at cable guide base (see figure 2-2).
from drum.
e. Remove winch cable from drum as follows: NOTE: The up limit switch should actuate
(1) Loosen Alien head setscrew securing before excessive cable pressure is applied to
cable end in drum anchor hole. Remove cable vertically compress bumper pad. Permanent
end from winch by pulling cable down through damage can result if rubber bumper pad is
cable guide, cable cutter, and bumper guide (see stowed in a compressed state over an ex-
figure 2-2). tended period of time; rubber bumper will re-
main in a compressed (set) state.

CAUTION: Anchor hole setscrew should be
temporarily tightened to prevent fouling winch
mechanism if winch is inadvertently operated.
(4) Install cover onwinch.
k. Perform an operational check of hoist sys-
tem (para 2-10).
(2) Retighten setscrew in anchor hole.
f. Remove swivel hook from cable (para 2-18).
Replacement cable must be 0.125-inchdiam-
g. 2-18. REPLACEMENT OF SWIVEL HOOK.
eter stainless steel, 19 by 7 cable strand, extra a. Remove swivel hook assembly (fig. 2-2)
strength, antispin cable with a minimum breaking from cable as follows:
strength of 1800 pounds. Make certain any re- (1) Remove rubber bumper covering swivel
placement cable, other than cable supplied by hook housing by pulling bumper upward off top of
winch manufacturer, is approximately 113 feet hook housing (see figure 2-2).
long, equipped with a swaged ballfitting, and
is (2) Remove cable swaged ball end fitting
is proof tested to a minimum load of 1350 pounds. from hook housing socket: pull cable swaged bail
h. Install swivel hook on replacement cable fitting through rubber bumper.
(para 2-18). b. Install swivel hook on cable as follows:
i. Attach new replacement cable to winch as (1) Lubricate cable
swaged ball end fitting
follows: with petrolatum (34, table 2-5, HMI Vol i).
(1) Insert free end of replacement cable up (2) Insert cable through top of rubber
through bumper pad guide center, bellmouth, bumper.
switch, cable cutter, and between cable rollers (3) Insert cable ball fitting in hook housing
in the cable guide assembly (see figure 2-2). keyway and socket.
2-7
CAUTION: Make certain hook bumper com- 2-20. INSTALLATION OF HOIST ASSEMBLY.
pletely covers hook housing.
2-21. To install the hoist assembly, proceed as
(4) Secure cable ball fitting in housing follows:
socket by sliding rubber bumper down over hook
housing. NOTE: If support tube fittings (26, 27, 30,
fig, 1-1) were removed from fuselage, re-
NOTE: Hook bumper should completely cover move nylon screws installed in support fit-
housing and bumper base will overlap inward ting attachment holes on fuselage.
around housing base by approximately 1/16
inch when fully seated on housing. a. If required, install winch support tube attach
fittings (26, 27, 28) on fuselage using screws (23?
2-19. REPLACEMENT OF (GUILLOTINE-TYPE) 28) and washers (24, 25, 29),
CABLE CUTTER. Cable must be b, Attach winch (22) to support tube (12) using
winch-~para 2-17) before guillotine-type cable bo~ts (21), washers (20), and nuts (19). Tighten
cutter can replaced. Replace a spent cable
be bolts (21) to a torque of 70-100 inch-pounds.
cutter guillotine on winch as follows: c. Attach link assembly (18) to support tube
(12~ using bearing pin (17), washer (16), and
WARNING: The cable cutter contains an ex- cotter pin (15).
plosive squib that is electrically fired. A i. (12) to fuselage
Attach winch support tube
protective short-circuiting electrical jumper fit~ngs (26, 27, 30) using quick-disconnect pins
should remain connected to cable cutter, not
installed on the winch, to eliminate possibility
of inadvertent accidental firing (see figure NOTE: Install pins in position shown.
2-2).
CAUTION: Check that all electrical power is
a. Disconnect two electrical wire terminal off tbeliminate possibility of inadvertent
lugs from spent cable cutter. firing of cable cutter.
b. Loosen two Alien head setscrews at side of
movable cable guide and remove spent cable cutter e. Remove protective cap from electrical re-
from guide, ceptacle on side of fuselage. Connect winch elec-
c. Check that all electrical power is OFF. trical plug (1, fig. 1-3) to fuselage receptacle.
Secure wire harness to support tube using tie-
WARNING: Do not use an ohmmeter or any straps (9, table 3-1).
other device containing an internal voltage
source which could fire cable cutter. WARNING: Remove protective electrical
jumper (fig. 2-2) from cable cutter
wire
d. Using a voltmeter, check for zero voltage whenever winch is installed on helicopter.
between electrical wiring terminal lugs; also Jumper wire will prevent operation of cable
check for zero current between lugs with a cutter in an:in-flight emergency.
milliammeter.
e. cylindrical end of new cable cutter
Insert 2-22. PREPARATION FOR HOISTING
into winch movable cable guide, with shorting OPERATIONS.
jumper positioned downward, and secure cable
cutter to guide with two Alien head setscrews. 2-23. Prepare helicopter for hoisting operations
Setscrew mates with indent on cable cutter. as follows:
f. Connect one electrical terminal lug to cable
cutter terminal, leaving protective short-circuit- CAUTION: To avoid inadvertent firing of
ing jumper installed on cable cutter. Then con- cable cutter, make certain cable cutter elec-
nect second wire to remaining cable cutter termi- trical circuits are not energized.
nal in the same way.
a. Connect external electrical power to
CAUTION: Protective jumper wire should helicopter.
remain connected to cable cutter electrical b.
Place BATTERY switch in EXT position.
terminals until hoist is to be used. c. Open passenger/cargo door;
extend and
secure door (hold-open) retainer tube.
g. Cover exposed electrical terminal areas d.

Using hoist system controlpendant, exer-
with sealing compound (3, table 2-5, HMI Vol cise winchby paying out 3 or 4 feet of cable under
1). approximately 15 pounds tension, ?ulling cable
2-8
straight down to avoid rubbing cable on cable bell- g. Check that winch support tube attach safety
mouth. Reverse control and reel cable in. Check pins are secure and fully seated.
that cable winds on winch drum evenly and that h. plug
Check that winch electrical connector
winch operation is smooth and consistent. Make is receptacle on side of fuselage.
secure on
certain winch stops automatically when top of i. Connect hoist system operators safety har-
swivel hook pushes against winch bumper pad. ness to seat belt fitting on opposite side of pas-
e. If installed, remove cable cutter jumper senger/cargo compartment from which winch is
wii;e (see figure 2-2, sheet 1). installed.
j. Place BATTERY switch in OFF position.
WARNING: Cable cutter jumper wire must k. Remove external electrical power from
be removed to allow cable cutter electrical helicopter.
circuit to be completed by switch control,
providing instantaneous in-flight cable cutting WIRING AND SCHEMATIC DIAGRAMS.
2-24.
capability should such emergency action be
required.
2-25. Figures 2-3 and 2-4 are wiring diagrams
f. If winch has not been used for an extended for the hoistsystems used on commercial and
period of time, or if cable has been replaced, military configuration helicopters, respectively.
perform an operational check (para 2-10). Figure 2-5 is a schematic diagram of the winch.
2-9
W3 BUS
i7 J28
A526A121 C
43 ,,,ct A
BI PT07C14-8S
CYCLIC STICK RECEPTACLE
CABLE CU~ER (MATES WITH
TB 10
PT06P14-8P
S600
7 1~2 PLUG)
CB6DO
M535A1210
hJ
(40 AMP)
JUMPER
AWG
M503820
TB1-16
r
A F --MIO]FM-- --r
P130
I 13-
lirnMPII ~Bi r--ICCtLII-

U
SPARE H
M504H20 I
E24 F
1
XJ2 rPENDENT
UP
CONTROL
I
CCIAA20 I I 1
A
HOIST
NOTES: I I I
a DOWN
i. TH IS DIAGRAM IS TO BE USED WITH ELECTRICAL SYSTEM WIRING DIAGRAM D

IN THE HMI-VOL 1 FOR COMPLETE CIRCUIT IDENTIFICATION. CUTTER
2. DASHED LINE ITEMS ARE PART OF HELICOPTER BASIC ELECTRICAL
SYSTEM.
,MS3101E 16S-1S
3. COMPONENT TERMINAL NUMBERS ARE FOR REFERENCE AN D MAY NOT BE RECEPTACLE
SHOWN ON COMPONENT.
4. REFER TO WINCH SCHEMATIC DIAGRAM FOR INTERNAL

CONNECTIONS.
47-275
Figure 2-9. Hoist system wiring diagram commercial configuration

2-10
CSP-029
CBbOO J28
1/ 2140 AMP)
A526A 12
SPLICING
A526A12--I C
PERMISSIBLE
riiOlST (E192----A527H20N i
A
11~2 ~A527J20N
---A526A12------L~ B
CB133 I I PTD7C14-8S
(40 AMP) I CYCLIC STICK RECEPTACLE
I
HO~IST CUT (CTR) CABLE CUTTER (MATES WITH
SWITCH S600 PTD6P14-8P
1~2
--M503A20- T WINCH PLUG
CB134
17.5 AMP) JLAEONLY
~5AMP _
.t-~,
t-t
CB601 P616 i TB1-40 TB1-19 P109
F--M5(14K20;B 7--M521F20-I
17.5 AMP)
o--M503A20-
a -IVlsbnn2o-~
(NOTE 5)
n
B
NOTE 6
A -M520F20-
_~
C LJ
dJ
H SPARE
E24)
[r XJ2C A
B
PENDANT CONTROLrRo~
UP
DOWN
CUTTER
HOIST
I
NOTES:
i. THIS DIAGRAM IS TO BE USED WITH ELECTRICAL SYSTEM WIRING D IAGRAM \MS3101E16S-1S

IN HMI-VOL 1 FOR COMPLETE CIRCUIT IDENTIFICATION. RECEPTACLE
2. GASHED LINE -I ITEMS ARE PART OF HELICOPTER BASIC ELECTR ICAL

SYSTEM.
3. COMPONENT TERM INAL NUMBERS ARE FOR REFERENCE AND MAY NOT BE
SHOWN ON COMPONENT.
4. REFER TO WINCH SCHEMATIC DIAGRAM FOR INTERNAL CONNECTIONS.
5. EXISTINGWIRE, RELOCATEDTOTB1-00A.
6. REMOVE EXISTING WI RE M520820.
47-276A
Figure 2-4. Hoist system wiring diagram military configuration
2-11
Section 2 Opt Eqpt Manual CSP;029
FULI-I N
P28 (NOTE) LIMIT SWITCHES
F AWC 20 ORN OR WHTlORC--ct-p BRAKE
UP DOWN
I I r
GI I AWG 12 WHT
I I I r---
61
AWG 1ZREOORWHTiRED
Ct I I I TC___~ i. ___-~
DOWN UP
MOTOR
FULL-OUT
LIMIT SWITCH
E (--------t-- AWC 20 YEL OR WHTIYEL

CABLE CUTTER
SAFETYJUMPERWIRE
ISEE WARN)NG)
I
D 20 GREEN OR WHTIGRN OR BLK
B 20 BLU OR WHSIBLU OR WHT
1 _
NOTE:
REFER TO HOIST SYSTEM INTERCONNECT- WARN INC: REMOVE JUM PER W I RE
ION WIRING DIAGRAM FOR EXTERNAL AFTER INSTALLATION OR MAIN-
CONNECTION. TENANCE (REFER TO TEXTI.
47 -277
Figure 2-5. Hoist system winch schematie diagram
2-12
SECTION 3
3-1. GENERAL INFORMATION. door sill

a antichafing bar assembly, a winch and
winch support tube assembly, and the electrical
3-2. SCOPE. The passenger/cargo hoist kit can wiring and components required for operation of
be installed on any
Hughes 500D (commercial) or the hoist system.
500MD (military) Model 369D helicopter. On
commercial helicopters, the hoist winch is in- 3-3. REFERENCE DATA. Information in the in-
stalled on the right side of the fuselage. On stallation instructions is presented as additional
military helicopters, the hoist winch is installed procedures to those given in the body of the Hand-
on the left side of the fuselage. Subsequent pro- book of Maintenance Instructions (HMI Vol i).
cedures provide separate inseructions for com- Reference is made in the instructions to the appli-
mercial and military electrical installations to cable data in the HMI Vol 1 that is to be followed
accommodate differences in component location in order to accomplish the installation of the hoist
and wire routing. A special cyclic grip kit must kit. Table 3-1 lists consumable materials and
be installed oh any Hughes 500D (Model 369D)
expendable items required for installation of the
helicopter when the hoist kit is installed. Znstal- hoist kit. Items listed are of a commercial na-
lation instructions include procedures for instal- ture that can be procured locally. Alternate but
ling a passenger/cargo door retainer assembly, equivalent items are acceptable.
Commerical Product(2)
Item
No. Material Specification(l) Name/No. Manufacturer
1 Terminal MS2503 6- 103 Commercially

available
2 Term inal MS25 03 6- 1 12 Co mm e re ially

available
3 Terminal MS25036-156 Commercially

available
4 Pin, contact MPCMSOM-HB Burndy Corp

Norwalk, CT
5 Pin, contact llPCM20M-ll2 Burndy Corp
6 Wire, electrical, white MIL-W-5086, AWG #20 General Cable Corp
Type Il Los Angeles, CA
7 Wire, electrical, white MIL-W-5086 AWG #12 General Cable Corp

Type II
8 Twine, nylon MIL-T-713 (3) Commerically

available
9 Tie-strap MS3367 AWG, size as Commercially

required available
3-1
Table 3-2. Consumable materials and expendable items (cont)
Commerical Product(a)
Item
Na. Material Specification(l) Name/No. Manufacturer
10 Insulation sleeving (heat- MIL- I- 23 053/5 RNF- 100, Type Raychem Corp
shrinkable) 1, AWG, size Menlo Park, CA
as required
11 Solder, tin alloy QQ-S-571 (3) Commercially

(Composition available
SN60WRP2)
12 Screw, nylon 1030-010-820 Cries Reproducer Co

New Rochelle, NY
13 Primer, zinc chromate MIL-P-8585 (3) Commercially

available
14 Tape, electrical, plastic MIL-I-7798 No. 33 3M Co., St. Paul, MN
NOTES: (1) Numbers are U. S. A.

Specifications and Standards. The prefix symbols are defined as
follows: AMSAmerican Material Standard; MS Military Standard; MIL Military
Specification; Single, double or triple alpha prefix of the same letter Federal Specifi-
cation; AN Air Force-Navy Aeronautical Standard; NAS National Aerospace Standard.
(2) Primary selection. Any equivalent material may be used as an alternate selection.
(3) Use the best comparable grade material when the conformity of available materials of
the same type with the listed Specification No. cannot be determined.
3-4. PREPARATION FORINSTALLATION. In- NOTE: Fuel vent must be removed to avoid
structions in the following paragraphs are appli- damage during structural modification hole
cable to both left and right hoist installations drilling operations.
except as noted.
a. Identify all components that are to be in- e. Remove crew compartment seat and back
stalled, along with those removed to gain access cushions.
to work areas. Protect components from damage f. Remove left (outboard) collective stick cover
and contamination. (sections 2 and 4, HMI Vol 1).
b. Check that all electrical switches are in g. Remove crew compartment lower aft trim
OFF position. panels (left and right) (section 4, HMI Vol 1).
h. Remove crew comparlment left or right
CAUTION: Make certain BATTERY switch is bulkhead panel and lower portion of right upper
in OFF position. side panel (section 4, HMI Vol 1).
i. Remove edgelighted panel face from lower
3-5. REMOVAL OF EQUIPMENT. and circuit breaker panel.
Loosen lower
switch and circuit breaker panel to accommodate
3-6. Remove following panels, access doors, installation of additional circuit breakers (sections
and equipment as applicable to accommodate in- 17 and 19, HMI Vol 1).
stallation of the hoist system components:
a. Remove battery (section 19, HMI
3-7. MODIFICATION.
Vol 1).
b. Remove left and right foot support fairings
inpassenger/cargo compartment (section 2, 3-8. Modification of the helicopter (fig. 3-1) in-
HMI Vol 1). volves Cutting a hole in the fuselage skin to facili-
c. Remove passenger/cargo compartment for- tate installation of an electrical receptacle (528)
ward bulkhead trim panel (commercial models) to receive a winch electricalplug, and a hole in
and controls access door (sections 2 and 4, HMI the lower left area of the canted bulkhead and fdr-
Vol i). ward bulkhead trim panel to facilitate installation
d. Remove fuel cell forward vent from control of an electrical receptacle (XJ2) to receive a con-
tunnel (section 12, HMI Vol 1). trol pendant plug.
3-2
I -i~- CUT HOLE IN SKIN TO ~-C9/

MATCH HOLE IN DOUBLER
HO I ST ELECTR ICAL
CONNECTOR DOUBLER
O la
CANOPY~ o
UPPER jJ
WINDSHIELD lo
0/
3/
CRIWCOMPARTMENT I!
RIGHT DOOR FRAME
NOTE:
COMMERICAL VERSION SHOWN. MILITARY

VERS ION IS INSTALLED AT SAME LOCATION
OF LEFT S I DE OF HEL I CO PTER.
COMMERCIAL CONFIZURATION
CUT 1.00 IN. HOLE IN SKIN O WINCH ELECTRICAL RECEPTACLE (!28) CUTOUT LOCATION (NOTEI
O O O O O O O
ol o o o o o_~-o -~-O O 00 O O
WL 21. 50
O O
i X!2 2.00IN. O
o
0. 970 IN.O/rT
(TYPICAL)-+ 13 c
O
O
T" le2. 00 IN.-~
-0-
O
O O O O O O O O O 8-0
1~ 2. 00 IN
O 0- i. 50 IN. O
XJ2
O
O O. 970 IN. O MILITARY CONFIGURATION
O (TYPICAL) CUT 1.DO IN. HOLE IN SKIN
o
o ojyo O 0. 121 0. 133 HOLE
VIEW LOOKING FORWARD LOWER LEFT 1 4 PLACES
CORNER OF CANTED BULKHEAD STA 78, 50 BL 20:75 LH
O PENOANT CONTROL LLtCrR ICAL REC~PTACLT CUTOUT LOCP~TION
47-278
Figure 3-1. Modification of helicopter
3-3
Section 3 Opt Eqpt CSPlio29
a. Cut and deburr holes, remove chips, and Install terminal (2) on wire P506AH12 and
apply a thin coat of primer (13, table 3-1) to install on contact 1 of CB600 together with jumper
exposed metal surfaces. wire fabricated in step d. above. Route wire

b. Fit forward bulkhead trim panel to canted P506AH12 to contact 7 o~f BUSS W3; cut wire to
bulkhead, locate and cut hole in trim panel to length and install terminal (3-). Connect wire
match XJ2 receptacle hole in bulkhead. Remove P506AH12 to contact 7 of BUSS W3.
trim panel to accommodate installation of door Install terminal (2) On wire M535A12 and
retainer assembly. connect wire to contact 1 of. TBlb. Route wire
M535A12 to contact 2 of CB600 and install termi-
NOTE: Hoist electrical connector (528) nal (3). Connect wire M535Ali to contact 2 of
doubler is located in the crew compartment, CB600.
below the aft lower of the upper canopy
corner g. Install terminal (1) on Wire M503B20 and
windshield, and immediately forward of the coni~ect to contact i.of~CBGO1. Route.
opposite
canted frame (station 78. 50) for either right end of wire M503B20 to TB1-16, install: pin (4)
side (commercial) or left side (military) hoist and insert pin in TBI:-16, contact A.
winch installation. h. Connect teaininal of wire A526A12 to TB10,
contact 1 and~route wire below Tloor through
3-9. INSTALLATION OF ELECTRICAL EQUIP- center beam, below crew compartment right
MENT (COMMERCIAL HELICOPTERS). ,right side aft of door frame to 528
seat and up
receptacle.
3-10. Install hoist kit electrical wire harness
NOTE: Temporarily tiewires inplace. Do
assembly, generalwiring, and components on
not cut wires until all wires are adjusted and
commercial helicopters as follows:
tied in place.
CAUTION: Make certain wires and/or i. Insert pin-of wire CC1OABO in TB1-16, con-
wire bundles do not chafe or bind control tact C. Connect terminal on shielding of wire
mechanisms. CC1OA20 to ground stud E24. Do not tighten
ground stud nut. Route wire CC1OA20 to 528 re-
NOTE: When providing ground contact for ceptacle and tie in place.
electrical components, clean the contacting Insert XJ2 receptacle (36, fig. 1-1) in hole
surfaces to bare metal (section 19, HMI provided in lower left corner of canted bulkhead
Vol 1). Route wire and wire bundles with (fig. 3-1). Using X52 receptacle bracket as a
existing wires and bundles. Temporarily tie template, mark anddri,llfour 0.:121 to 0. 133
wires in place with existing bundles until in- attach holes.. Protectattached wires during drill-
stallation is complete, then secure wires with ing operation. Install XJ2 receptacle (36, fig.
permanent twine, tie-straps, or clamps as 1-1) from forward side of canted bulkhead, with
required. screws (35), washers (34), and nuts (33).
k. Route wires CC1AAB0 and CC2A.A20 (fig.
Install cyclic stick grip kit (47, fig.
a. 1-1). 2-3) from X52 receptacle to TB1-16; install pin
(Refer to applicable Opt Eqpt Manual. of wire CC1AAB0 in contact B and pin of wire
b. From inside crew compartment, tempo- CC2AA20 in contact D. Connect Terminal on
rarily install 528 receptacle (39, fig. 1-1), shielding of wire.CC2AA20 to ground stud E24;
through hole provided in right side of ship (fig. tighten ground stud nut.
3-1). Install washer (38, fig. 1-1) and recep- Route wires CC8A20 and CC9A20 to 528 re-
i
tacle nut externally to retain 528 receptacle in ceptai~leand tie in place.

place. m. Cut and strip wires at 528 receptacle, En-
sure sufficient wire length to provide a smooth
NOTE: The 528
receptacle is temporarily right angle wire flow to 528 receptacle. Install
installed to provide a means of determining approximately 6 inches of 0. 50 insulation tubing
wire length to receptacle. (10, table 3-1) on wire bundle to cover all wires
extending from 528 receptadle. Ensure that all
c. Install circuit breakers (31, 32, fig. 1-1) electrical contact installations are correct and
in positions CB601 and CB600 respectively, on secure. A.djust wires at 528 receptacle and make
lower switch and circuit breaker panel. certain sufficient wire slack remainsto avoid
d. Refer to figure 2-3and install terminal stress on terminals and-contacts belowifloor and
(1, table 3-1) on circuit breaker jumper wire; seat areas. Use twine,(8) and tie-straps (9), to
install jumper wire on contact 1 of CB601. secure wires in place.
3-4
CAUTION: Make certain that wires do not c. On SLAE equipped military helicopters with
chafe or bind, throughout full travel of any 369D294566 circuit breaker panel, install circuit
control mechanism. breaker CB133 (32) and circuit breaker CB134
(31), in circuit breaker panel located on the pilots
n. Remove 528 receptacle from side of ship, collective pitch stick cover. Make certain circuit
Install insulation sleeving (10, table 3-1) using breaker connections to buss bar are secure.
solder (11), A526A12, A527G12N,
connect wires d. Refer to figure 2-4 and install terminal (3,
A527H20N, A527J20N, CC1OA10, CC8A20, and table 3-1) on wire A526A.12 and connect to contact
CC9A20 to 528 receptacle contacts as indicated 2 of CB600 on standard military helicopters, or
in figure 2-3. to contact 2 of CB133 on SLAE equipped military
_o. Install 528 receptacle and secure with helicopters. Route opposite end of ~ire A526A12
washer and nut. Install protective cap (37, fig. with existing wire bundles to 528 receptacle and
1-1. temporarily tie in place.
p. Install ground stud 40 thru 43) on forward On standard military helicopters, locate
siae of canted bulkhead frame (fig. 3-1). Identify existing wire M503A.20, install terminal (1) on
Ground stud as E19. wire M503AZO, and connect to contact 2 of CB602.
q. Installwires A527G12N, A527H20N, and Locate existing wire M503AA20, remove from
A527J20N, from 528 ground stud
receptacle, on TB16, contact A., and relocate to TB1-40, contact
E19. Adjust and trim insulation tubing to accom- A.
modate ground wire connection as required; heat On SLA.E equipped helicopters, install pin
shrink tubing. (5) on wire M503A20,
insert pin in contact A of
TB1-40. Route wire M503A20 to CB134; install
3-11. INSTALLATION OF ELECTRICAL EQUIP- terminal (1) and connect to contact 2 of CB134.
MENT (MZLITARY HELICOPTERS). g. Install pin (4) on wire M504K20, insert in
contact B of TB1-19, and route opposite end of
3-12. Install hoist kit electrical wire harness wire M504K20 of TB1-40. Install pin (4) and
assembly, generalwiring, and components on insert pin in contact A of TB1-40.
military helicopters, as follows: h. Remove existing wire M520B20 from TB1-
19A. Wire end is left open insulated with tape
CAUTION: Make certain wires and/or (14), and secured to basic electrical system with
wire bundles do not chafe or bind control tie-strap (9). Install pin (4) on wire K504M20
mechanisms. and insert in contact A of TB1-19. Route wire
K504M20 to TB1-40, install pin (4), and insert
NOTE: When providing ground contact for pin in contact C of TB1-40.
electrical components, clean the contacting Insert pin of wire CC1OAB0 in contact C of
surfaces to bare metal (section 19, HMI TB1-40, route wire to 528 receptacle, and tempo-
Vol 1). Route wire and wire bundles with rarily tie in place. Connect terminal on shielding
existing wires and bundles. Temporarily tie of wire CC1OA20 to ground stud E24. Do not
wires in place with existing bundles until in- tighten ground stud nut.
stallation is complete, then secure wires with j. Insert XJ2 receptacle (36, fig. 1-1) in hole
permanent twine, tie-straps, or clamps as provided in lower left corner of canted bulkhead
required. (fig. 3-1). Using XJ2 receptacle bracket as a
template, mark and drill four 0. 121 to 0. 133
a. From inside crew compartment, tempo- attach holes. Install XJ2 receptacle (36, fig. 1-1)
rarily install 528 electrical receptacle (39, fig. from forward side of canted bulkhead, using
1-1) through hole provided in left side of ship screws (35), washers (34), and nuts (33).
(fig. 3-1). Install washer 38, fig. 1-1) and re- k. Route wires CC1AA20 and CC2AA20 (fig.
ceptacle nut externally to retain 528 receptacle 2-4) from XJ2 receptacle to TB1-40, install pin
in place. of wire CC1AA%O in contact B, and pin of wire
CC2A.A20 in contact D. Contect terminal on
NOTE: The 528 receptacle is temporarily in- shielding of wire CC2A.A20 to ground stud E24;
stalled to provide a means of determining tighten ground stud nut.
Droper length of wires to be connected to i. Route wires CC8A20 and CC9A20 to 528
receptacle. receptacle and temporarily tie in place.
m. Cut and strip wires at 528 receptacle. En-
b. On standardmilitary helicopters, equipped sure sufficient wire length to form a smooth right
with 369B92143 circuit breaker panel, install angle wire flow to 528 receptacle. Install approx-
circuit breaker CB600 (32, fig. 1-1, view B), and imately 6 inches of 0. 50 insulation tubing (10,
a circuit breaker CB601 (31) in circuit breaker table 3-1) on wire bundle to cover all wires ex-
panel located on the pilots collective pitch stick tending from 528 receptacle. Ensure that all
cover. Make certain circuit breaker connections hoist system electrical installations are correct
to buss bar are secure. and secure. Adjust wires at 528 receptacle and
3-5
make certain sufficient wire slack remains to Use angles (16, fig. 1-2) as templates and deter-
avoid stress on terminals and contacts below mine rivet hole locations on station 78. 50 bulk-
floor and seat areas. Use twine (8), and tie- head. Drill rivet attach holes, 0. 069- to 0. 074-
straps (9), to secure wires in place. inch diameter, usingdrill motor and appropriate
drillbit. A.ttach angles (16) to 78. 50 bulkhead
CAUTION: Ensure that wires do not chafe using rivets (14, 15).
or bind throughout full travel of any control b. Position structural reinforcement brackets
mechanism. (13~ onforward side of station 78.50 canted bulk-
head as shown in figure 3-2. Locate nine exist-
n. Remove 528 receptacle from side of ship, ing rivets which must be removed prior to instal-
Install insulation sleeving (10, table 3-1) and lation of reinforcement brackets. Remove rivets
using solder (11), connect wires A526A.12, using drill motor and appropriate drillbit. Use
A527G12N, A527H20N, A527J20N, CC1OAIO, brackets (13, fig. 1-2) as template and determine
CC8A20, and CC9A.20 to 528 receptacle contacts rivet hole locations on 78.50 bulkhead. Drill
as indicated in figure 2-4. rivet attach holes, 0.069- to 0.074-inch diameter
o, Install 528 receptacle and secure with using drill motor and appropriate drillbit. Attach
washer (38, fig. 1-1) and nut. Install protective brackets (13) to 78. 50 bulkhead using rivets (11,
cap (37, fig. 1-1). 12).
Install ground stud (40 thru 43) on forward
p. c. Using drill motor and appropriate drill bit,
si~e of canted bulkhead frame (fig 3-1). Identify driil eight 0.190- to 0.199-inch diameter holes
ground stud as E19. through station 78.50 canted bulkhead and struc-
Install wires A527G12N, A527H20N, and tural reinforcement angles (16) and brackets (13)
A527J20N, from 528 receptacle on ground stud at locations shown in figure 3-2.
E19. Adjust and trim insulation tubing to accom-
modate ground wire connection as required; heat NOTE: Drill retainer tube outboard clamp
shrink tubing. holes install retainer tube and out-
first;
board clamps to ensure proper alignment
3-13. ASSEMBLYOF HOIST. for marking and drilling inboard clamp holes.
3-14. assembly consists of a winch as-

The hoist d. Install the retainer assembly (17, 18, 19,
sembly, pendant assembly, hook hanger,
control fig. 1-2) on station 78. 50 canted bulkhead using
and two attach brackets. To assemble the hoist, clamps (10) washers 7, 9), spacers (8), screws
proceed as follows: (6), and nuts (5).
e. Locate bracket (4) on applicable passenger/
NOTE: Pendant assembly is shipped assem- cargo door in such a manner as to allow tube (17)
bled with no additional assembly required. to engage bracket (4) when door is in open posi-
tion. Install bracket (4) on passenger/cargo door
Installhanger(l, fig, 1-3)onwinch(9)
a. frame using rivnuts (3), washers (2), and screws
using screws (6~. lockwashers (5), and washers (1).

(4).
b. Remove existing attach brackets from winch 3-17. INSTALLATION OF HOIST.
(9), Install replacement brackets (2, 3) on winch
frame using existing hardware. 3-18. The hoist system winch is mounted on a
support tube and attached with quick-release
"afety pins to three fittings installed on either
3-15. INSTALLATION OF PASSENGER/CARGO
side and above the passenger/cargo compartment
DOOR RETAINER.
door. The support tube positions the winch to
raise and lower the cable between the side of the
3-16. The passenger/cargo door retainer instal- fuselage and the landing gear skid. The winch
lation consists of a tubular assembly attached to and support can be installed for use on either the
the aft side of station 78.50 canted bulkhead with left or right side of the helicopter as applicable.
four clamps. With the passenger/cargo doors in Install the hoistsystem as follows:
the open position, a telescoping tube slides out of a. Removenylon screws installed in support
the tubular assembly
to engage a bracket attached fitting attachment holes on fuselage.
to the door frame and thus retains the door in an Install support tube
b. attachment fittings (26,
open position. Install the passenger/cargo door 27, 30, fig. 1-1) on fuselage using screws (23,
retainer as follows: 28) and washers (24, 25, 29).
a. Locate doubler angles (16, fig. 1-2) on for- :Attach winch (22) to support tube (12) using
ward side of station 78.50 canted bulkhead using bolts (21), washers (20), and nuts (19). Tighten
twoexisting O.OlO-inch tooling holes (fig. 3-2). bolts (21) to a torque of 70-100 ipch-pounds.
3-6
CSPi029 Opt Eqpt Manaul Section 3
~j
EXISTING~ 1
~OOOL::NG BL n~
ii
22.60 o
INCHES
1
DOUBLER ANGLE IN
j
1 f
II\ WL
34.36
REMOVEEXISTING
RIVETS 9 PLACES
O REINFORCEMENT BRACKET
STRUCTURAL RE1NFORCEMENT LOCATION
WL
21.50
PASSENGER/CARGO
REINFORCEMENT DOOR RETAINER TUBE 0. 190-0. 199
BRACKET r?Sq
HOLES PLACES
i .I.i
c,s
34.36
lio
lo
i/j
oil
8L
22.60
O DOUBLER ANGLE
PASSENGERICARGO DOOR RETAINER

BL
TUBEALIGNMENTANDATTACHMENT
6.50
(V IEW LOOKING FORWARD-LEFT S(OEI 07-287
Figure 3-2. Passenger/cargo door retainer tube installation
3-7
Section 3 Opt Eqpt Manual CSP-029,
d. Attach link assembly (18) to support tube (4) Align chafing bar aft screwhole with aft
(12) using bearing pin (17), washer (16), and abrasion strip aft attach hole; install screw
cotter pin (15). (NAS603-8) to secure aft portion of chafing bar.
e. (12) to fuselage
Attach winch support tube (5) Hold chafing bar against skid; locate bar
fittings (26, 27, 30) using quick-disconnect pins forward screwhole over forward abrasion strip
aft attach hole; drill 0. 190 to 0. 200-inch screw-
hole through chafing bar.
NOTE: Install pins in position shown in fig. (6) Install screw (NAS603-8) to secure for-
1-I. ward end of chafing bar.
CAUTION: Check that all electrical power 3-19. INSTALLATION OF EQUIPMENT.

is off, eliminating possibility of inadvertent
firing of cable cutter. 3-20. Install equipment and panels as follows:
f? Remove protective cap from electrical re- CAUTION: Remove all tools and foreign
ceptacle on side of fuselage. Connect winch materials from helicopter before panel
electrical plug (1, fig. 1-3) to fuselage recep- installations.
tacle. Secure wire harness to support tube using
tie-straps (9, table 3-1). a. Prior to closing access areas, check entire
hoist system installation for completeness.
WARNING: Remove protective electrical b. Install edgelighted and circuit breaker
jumper wire (fig. 2-2) from cable cutter panels as applicable (sections 17 and 19, HMI
whenever winch is installed helicopter.
on Vol i).
Jumper wire will prevent operation of cable c.: Install crew compartment left or right bulk-
cutter in an emergency. head panel and lower portion of left or right upper
side panel as applicable (section 4, HMI Vol 1).
I"stall the hoist operators body harness d. Install crew compartment lower aft trim
(10, fig. 1-1). panels (left and right) (section 4, HMI Vol 1).
h. Install flush rivets (7) in wheel fittings e. Install left (outboard) collective stick cover
after removing existing rivets from locations (sections 2 and 4, HMI Vol i).
shown in fig. 3-3. f. Install seats and back cushions.
g. Inpassenger/cargo compartment, install
NOTE: Do not install rivets (7) if wheel fuel cell forward vent in control tunnel
(section 12,
fittings have been previously equipped with HMI Vol 1).
flush rivets. h. In passenger/cargo compartment, install
controls access door and foot support fairings.
i. Install rivnuts (8) at locations shown in fig.
3-3. Secure clips (7, fig. 1-1) to fuselage using
NOTE: (station 78.50)
The forward bulkhead
trim panel is not installed
during use of the
screws (5), and washers (6). Install bar assem-
hoist system door retainer equipment.
bly (4) using screws (3), washers (2), and nuts
(1).
On
military configuration, install landing i. Installbattery (section 19, HMI Vol 1).
gear skid chafing bar assembly (369D292556) as Perform operational check of hoist system
follows (see fig. 3-3): (para 2-10).
(1) Remove bolts from inboard side of aft
abrasion strip (369116102), and aft bolt from in-
3~21. WEIGHT AND BALANCE.
board side of forward abrasion strip (369B6102),
on left landing gear skid.
(2) Install screw (NAS603-8) in forward 3-22. The weight,and balance changes resulting
attach hole of aft abrasion strip (369B6102). from installation of the passenger/cargo hoist
(3) Position chafing bar on inboard side of system are listed in table 3-2. After installation
left skid with bent end of bar aft, and 3/8-inch of the hoist system, incorporate changes in the
diameter recess hole in chafing bar over aft helicopter weight and balance records as in-
abrasion strip forward attach screw, structed in HMI Vol 2.
3-8
Item Weight (Ib) Arm tin. Moment tin. -lb/100)
-521 Kit (Military)

Added 42.3 98.0 4152
Removed
Changed 42.3 98.0 4152
-522 Kit (Commercial)

Added 39.3 98.7 3879
Removed
Changed 39.3 98.7 3879
3-9
WHEEL FITTI
I~ I
_i LANDING GEAR SKID/

(INBOARD SIDE)
\REMOVE EXISTING RIVETS
2 PLACES, INSTALL FLUSH
RIVETS
O CABLE ANTI-SNAG PROVISIONS

(ROTATEDI
FORWARD ABRASION
AFTABRASION
STRIP
STRIP
00
LEFT SKID (INBOARD

SIDE)
CHAFING
LEFT LANDING GEAR SKID CHAFING BAR PROVISION

(MILITARY CONFIGURATIONS ONLY)
INSTALL RIVNUT STA STA

2 PLACES 96.92 85. 69
1. 12 JACK FITTING\ I I I 1. 12
7 TT~ rr7 TT~ TT~ TT~.----

r-----,
I I \I I I I
\I I
I/.-----, II
I II
11Z
I,
I
;I
I I
I I I
I I
jl I
16. 03 11. 20
STA
112.92
d DOOR SILL ANTI-CHAFING BAR PROVISIONS
47-279A
Figure 3-3. Cable antichafing bar installation
3-10
CSP
032

and
Maintenance Insfructions
with Initial Installation instructions
FOR
SEARCHLIGHT INSTALLATION
PartNo. 369B90142
Hughes HelicOpters
COD772101 Issued 1 December 1977

IV1 FG.
INTRO
IN)tll LIICII CHANGED PIGLS, DC~1ROI SUPEISEDED PACES.

LIST OF EFFECTIVE PAGES THE ASTERISK INDICATES PAGES CHANGED.
i
ADDED. OR DELETED BY THE CURRENT CHANGE.
Title Original 1-1 thru 1-5.......,...., Original

A tllru B................ Original 1-6 Blank Original
C Blank Original 2-1 thru 2-5 Original
i Original 2-6 Blank Original
F-l Original 3-8 Blank Original
F-2 Blank Original
HUGHES TECHNICAL MANUAL RECOMMENDED CHANGE REPORT
revisions.
Hughes Helicopters

2T17B
Originator
Address
Figure Number(s)
Remarks/necomm endations
B/C
RECORD QF REVISIONS
CSP-032
MFG REV

CSP-OS1 Opt Eqpt Manual Table of Contents
SEARCHLIGHT INSTALLATION
TABLE OF CONTENTS
Section Page
FOREWORD F-l
F-l. Purposeand Content

of this Manual......... F-l
F-3. Applicability F-1
Combined Optional
Equipment F-l
F-7. Organization of Cohteds F-l
F-9. Use of this Manual...... F-l
F-11. Related Pubiic?tions..... F-l
Revisions F-r
1-1. Scope and Contents......

1-3. Group Assembly
Parts List 1-1
Illustrations 1-1
1-7. Usable On Code........ 1-1
2-1. General Lntormation..... 2-1

SEARCHLIGHT 1NSTALLATION
TABLE OF CONrENTS
Section Rage
(CONT)
2-6. Operational Check....... 2-1

2-8. Removal of Searchlight
Components 2-1
2-13. Repair 2-1
2-15. Installation of Searchlight
Components 2-4
2-18. Replacement of Searchlight
Lamp. 2-4
2-20. Wiring Diagram.......;. 2-5
3 INSTALLATION INSTRUCTIONS... 3-1

Equipment 3-3
3-7. Modification of Helicopter 3-3
-3-9. Installation of Searchlight
Hit ..............r.. 3-3
3-17. Installation of Helicopter
Equipment 3-7
3-19, Weight sand Balance Data... 3-7
FOREWORD
F-l, PURPOSE AND CONTENT OF THIS Each section is organized to provide comprehen-
MANUAL. sive coverage of entire systems, major equip-
ment groupings, and major components that are
F-2. This manual supplements information con- similar or associated. Procedures for each of
tained in HMI- Vol 1 and 369D- IPC, and contains these are presented in sequence as defined in
instructions for initial installation and continuing section 1, HMI Vol 1.
maintenance for the searchlight installation.
Weight and balance data is included. This manual F-9, USE OF THIS MANUAL.
also contains parts lists for procuring replace-
ment parts for the searchlight installation. F-10. This manual is foruse by operators of the
model 369D helicopter equipped with a searchlight
F-3, APPLICABILITY. installation. Although this manual is a separate
publication, it should be kept with HMI Vol 1,
F-4. The searchlight installation is applicable HMI Vol 2, 369 D IPC and other handbooks
for use on anyHughes 500D (Model 369D) listed in section 1, HMI Vol 1 that form the
helicopter. primary information file for the helicopter,
F-5. COMPATIBILITY OF COMBINED F-ll, RELATED PUBLICATIONS.

OPTIONAL EQUIPMENT.
F-6. Forcompatibility information on which of HMI Vol 1, 369D IPC and applicable Opt
optional equipment may or may not be used in Eqpt Manuals as required to accomplish instruc-
combination at the same time, refer to section 21, tions contained herein.
HMZ-Voll.
F-13. LITERATURE CHANGES AND REVlSIONS.
F-8. The contents of this manual are grouped manual are made as defined in section i, HMI
into sections as outlined in the Table of Contents. Vol 1.
F-1/F-2
SECTION 1
ILLUSTRATED PA#TS LIST
1-2. This illustrated parts list provides, by 1-6. Isometric illustrations are provided for
means of text (parts lists) and companion illus- each group assembly parts li$t. Each illustration
trations, a complete parts definition of the search- is exploded to the extent necessary to show parts
light installation configuration, manufactured by relationship for the searchlight installation.
1-7. USA~LE ON CODE.
NOTE: The illustrated parts list is organized
and presented in the same manner as the 3690 1-8. The USABLE ON CODE column located
Series Illustrated Parts List (3691) IPC). at theright-hand side of the Group Assembly
(For information on use, refer to 3690 IPC. Parts List pages indicates the effectivity of parts
by aircraft serial number. In many cases two
1-3. GROUP ASSEMBLY PARTS LIST. different parts are listed, representing the
one
orig~nal installation and another representing an

1-4. The parts list furnish information for pro- improved replacement item. Alphabetic codes
curing replacement parts for the searchlight are used to indicate the aircraft serial number
installation and shall not be used for any other applications of a given part. When no USABLE
purpose. For information orprocurementof ON CODE is listed, items are understood to have
other repla~ement parts, refer to the 3690 IPC. full effectivity.
1-1
22
30\
31 a~ i hlE~
29
30 5
10
I
I B
16
38~7
to
ii
3
II
d 24
a
9
39 15 13
O ACCESS COVER AND FLOOR WEB
O SEARCHLIGHT ASSEMBLY
47-292-1
Figure 1-1. Manually operated searchlight installation (sheet 1 of 2)
1-2
35 76 27
62
o 49 57
~dS
50t~t 59
6
Q D 52
8 e~63
b
O
75 65
O LOWER SWITCH AND

72 54
CIRCUIT BREAKER PANEL 74
71
":f/i~
66
63
77
53
69
79IJ
13
61 13
12
16 IS
Uou
21 66
O CARGO COMPARTMENT REENFORCEMENT
O LAMP ASSEMBLY
47-292-2
Figure 1-1. Manually operated searchlight installation (sheet 2 of 2)
1-3

INDEX PART 1 DESCRIPTION PER ON
NO. NO. ASSY CODE
1-1- 3691190142-501 SEARCHLIGHT INSTALLATION, I 1

MANUALLY OPERATED
-1 A3-20 I STUD 1 3
-2 GH3 I GROMMET 1 3
-3 S3-150 I SPRING 3
-4 NAS1097AD3 I RIVET 6
-5 A3-20 I STUD 6
-6 GH3 I GROMMET 1 6
-7 3691192142 1 FILLER. 6
-8 S3-150 1 SPRING 6
-9 NAS1097AD3 RIVET 1 12
-10 A3-20 I STUD 1 3
-11 GH3 I GROMMET. 3
-12 S3-150 I SPRING 3
-13 MS20426AD3 i RIVET........................... 6
-14 MS20470AD4 RIVET. 6
-15 369B90142-25 1 ANGLE 3
16 36 9B90142- 5 COVER, ACCESS 1
-17 369B90142-71 1 DECAL 1
-18 369B90142-69 1 DECAL 1
-19 NAS1101- 10 1 BOLT 4
-20 AN960-416 WASHER 4
-21 NAS 1291-4 1 NUT 4
-22 500-A I SEARCHLIGHT ASSEMBLY. 1
-23 1 4580 1 LAMP 2
-24 31945-1 LAMP ASSEMBLY (DS401-DS402) 2
-25 MS25244-35 1 CIRCUIT BREAKER (CB127)............ 1
-26 2TC12-5 CIRCUIT BREAKER (CB128)............ 1
-27 MS25041-8 1 LIGHT ASSEMBLY (XDS11). 1
-28 AN3140-327 LAMP 1
-29 MS20470AD3 RIVET. AR
-30 3691190142-13 STRAP 2
-31 3691190142-15 STRAP 2
-32 369B90142-49 PAN, FLOOR 1
-33 36 91190142- 3 WEB 1
-34 3691190142-51 1 ANGLE 2
-35 369B90142-23 1 ANGLE 1
-36 369B90142-24 1 ANGLE 1
-37 369B90142-9 1 CHANNEL 1
-38 369B90142-10 1 CHANNEL 1
-39 3691190142-43 1 FILLER. 1
-40 369B90142-19 1 ANGLE 2
-41 369B90142-7 1 CHANNEL 1
-42 AN3-12A BOLT 2
-44 NAS1291-3 I NUT 2
-45 111835206-245 1 SCREW 4
-46 AN960-8 I WASHER 4
-47 369B91042-47 1 CLAMP, HALF 2
-48 369B91042-17 1 SEAL 1
-49 NAS1104-9 I BOLT 4
-50 AN960-10 I WASHER 8
-51 NAS1291-4 NUT 4
-52 3691190142-41 PLATE, BEARING 1
1-4

NO. NO. ASSY CODE
1-1-53 369B90142-65 STRIP, CHAFE 1

-54 369B90142-59 1 BUS 1
-55 NASG 02- 5B SCREW 4
-57 MS24166D1 RELAY (K302-K303) 2
-58 NAS1096-3-12 I SCREW 1
-60 AN935- 10L I LOCKWASHER 1
-61 NAS671- 10 JA~JZNUT 1
-62 MS21042L3 I NUT 1
-63 MS20470AD3 RIVET I 11
-64 NAS1738B4 RIVET 1 6
-65 369B90142-55 1 SUPPORT, NUTPLATE 1
-66 36 91190142- 57 1 ANGLE 1
-67 MS20426AD3 RIVET 1 8

-68 NASG 96 A08 I NUTPLATE 1
-69 NAS1068A08 I NUTPLATE 3
-70 MS20470AD4 I RIVET 3

-71 MS20426~1D3 I RIVET 1 2
-73 369H90142-35 1 BRACKET 1
-74 36 9B90142- 33 BRACKET I 1
-75 369B90 142-39 ANGLE 1
-76 369B90142-37 1 ANGLE 1

-77 36 91190142- 31 SUPPORT 1
-78 369B90142-29 1 CHANNEL 1
-79 3691190142-27 1 CHANNEL 1

-80 369B90142-45 DOUBLER 1
1-5/1-6
SECTION 2
2. i. GENERAL INFORMATION. a. Hoist or jack up helicopter as specified in

HMI Vol 1 until landinggear skids or floats are
2-2. DESCRIPTION. The searchlightinstalla- approximately 2 feet above ground.
tion control column
of a b. Place BATTERY-OFF-EXT PWR switch at
mounted in the floor on the right side of the pilot s BATTERY position.
compartment, dual lights positioned outside of c. Using slidelock, extend searchlight to full
the compartment just below the control column, downposition. SEARCHLIGHT EXTcaution light
and an extendable support column for connecting on lower switch and circuit breaker panel should
the dual lights to the control column. A manu- come on and stay on.
ally operated slidelock, located on the control Usingcontrol handle, check movement of
column and attached to the extendable support dual lights in forward aft, and tilted positions;
column, is used to lower and extend the dual then return lights to forward and level position.
lights below the landing gear skids orfloats dur- Lights should not impinge on skids or floats.
ing flight. A handle on the control column is used CAUTION: When installed in conjunction with
to position the lights fore and aft, as required,
floats, searchlight must be fully extended before
and can also be rotated in place to tilt the exter-
dual lights are turned on, or damage to floats
nal lights downward approximately 1200. The
may result. Do not allow lights to remain on
tilting action is accomplished by a two-piece
longer than necessary to verify operation.
shaft installed inside the control and support
columns; the upper shaft is attached to the gear e. Place SEARCHLIGHT ON-OFF switch on
mechanism in the controlhandle, and the lower control column at ON position. Check that dual
shaft (which telescopes over upper shaft) is lights come on, then place switch at OFF position.
attached to the gear mechanism in the dual light f. Using slidelock, secure searchlight in full
assembly. A switch inside the control column uppositlon, SEARCHLIGHT EXT caution light
is actuated whenever the searchlight is moved on circuit breaker panel should go off.
out of the full up and locked position (by the g, Place BATTERY-OFF-EXT PWR switch at
slidelock), and causes the SEARCHLIGHT EXT OFF position.
caution light on the instrument panel to come on. 11 Lower helicopter with jacks or hoist as
Other controls provided for the searchlight con- specified in HMI Vol I.
sist of the SEARCHLIGHT PWR and CONT cir-
2-8, REMOVAL OF SEARCHLIGHT
cult breakers on the instrument panel, and the
COMPONENTS.
SEARCHLIGHT ON-OFF switch on the control
column. 2-9. SEARCHLIGHT ASSEMBLY.
a. Open SEARCHLIGHT PWR and CONT cir-
2-3. REFERENCE DATA. Information ;i~er- curt breakers (25, 26, fig. 1-1) on lower switch
taining tohelicopterstructural components which and circuit breaker panel. Tag circuit breakers
interface with the searchlight installation is in as required.
the Structural Repair Manual (369D-SRM). In- Verify BATTERY-OFF-EXT PWR switch
formation pertaining to standard helicopter equip- at OFF position.
ment is in HMI Vol 1 and 369D IPC. c. Loosen studs on floor access Cover (16, fig.
1-7), just aft of searchlight control column, and
remove cover.
d, Locate searchlight wiring on control and
support columns (fig. 2-1) and disconnect wiring
2-5. Use information provided in table 2-1 for at splices SP66 and SP67, ground terminal E27,
troubleshooting the searchlight installation, and relays K302 and K303, Tag wiring for
installation.
2-6, OPERATIONAL CHECK. e. Remove clamp and seal from external wiring
cable at bottom of fuselage, then remove cable,
2-7. With helicopter on~ground, perform opera- Remove bolts (19, fig. 1-1) from searchlight
tional check of searchlight system as follows: control column upper hearing plate at floorlfne.
2-1
SEARCHLIGHT
ON-OFF
SWITCH, CONTROL HAN DLE
SWITCH
HOUSING I
CONTROL V( )I(~ YJ-EXTENDIRETRACT SLIDELOCK
COLUMN
SPRING
PIN
FLOOR
FLOOR ACCESS COVER
PAN
UPPER BEARING PLATE

WIRING (NOTE 1)
RDTATIONALLOCK
dj
SEAL
INTERNAL SHAFT
KEY--~jlj .SUPWRT
LOWER BEARING PLATE
SETSCREW "O ~a CLAMP
SLIDELOCKPIN BVS
ATlACHMENTHOLE
EXTENDABLE
SUPPORT COLUMN
WIRING rNOTI 21~ NUTPLATE SUPPORT
INTERNAL SHAFT KEYWAY
LOWER FUSELAGE SKIN
EXTERNAL WIRING CABLE
K302 AND K303 RELAYS
EZ7GROUNDSTUD
ROTATING
BLOCKS~, C=7A 1~9;/ LAMP HOUSING
NOTES:
1. CONTROL COLUMN WIRING GOES TO

SPLICE SP66, SPLICE SP67, K302
RELAY, AND E27 GROUND STUD.
2. SUPPORT COLUMN WIRING GOES TD
RELAY K302, RELAY K303, AND
EZ7 GROUND STUD.
47-293
Figure 2-1. Searchlight installation
2-2
Table 2-1. Troubleshooting searchlight installation
Sympton Probable Trouble Corrective Action
Looseness in slidelock; lower Setscrew not seated properly Reset setscrew so that it is
support column will not stay in retaining hole of slidelock seated in retaining hole of
in retracted position pin, or setscrew not tight. slidelock pin. Tighten
(SEARCHLIGHT EXT caution setscrew.
comes on).
light
SEARCHLIGHT EXT caution Lamp in EXT caution light Replace lamp in EXT caution
light does not come on when assembly cap is burned out or light assembly cap.
searchlight is extended or not missing.
fully retracted.
External searchlights will not Setscrews in searchlight Tighten setscrews in search

stay adjusted in elevation. rotating blocks loose on inner light rotating blocks.
shaft.
Toggle arm or SEARCHLIGHT Excessive force applied to Replace switch.

ON-OFF switch broken or arm or arm hit by heavy
inoperative. object.
NOTE: Upper bearing plate is incorporated in b. Remove SEARCHLIGHT PWR and CONT
searchlight assembly and cannot be removed circuit breakers (25, 26, fig. 1-1) and EXT cau-
from control column, tion light assembly (27, 28) from lower switch
and circuit breaker panel as follows:
g. Hoist or jack up helicopter as specified in (1) Remove screws and lower switch and
HMl Vol 1 until landing gear skids or floats circuit breaker panel from instrument panel for
are approximately 2 feet above ground. access to circuit breakers and light assembly
4 Pull and extend slidelock and lower slightly (HMI Vol 1).
for access to setscrew, which secures slidelock (2) Tag and disconnect wiring from
pin to top of extending support column (fig. 2-1). SEARCHLIGHT PWR and CONT circuit breakers.
Remove circuit breakers from panel.
CAUTION: Take care to prevent searchlight (3) Tag and disconnect wiring from
support column land dual lights) from dropping SEARCHLIGHT EXT caution light assembly.
to ground when slidelock is removed. Also, Remove light assembly from panel.
care should be taken to retain slidelock pin c. Remove SEARCHLIGHT ON-OFF switch
which is under spring tension. (fig. 2-1) from control column as follows:
(1) Remove screws and housing for access
i. Loosen slidelock setscrew and remove to switch.
slidelock housing, spring, and lockpin. (2) Disconnect wiring and remove switch
Carefully lower searchlight support column from housing.
and raise interior control column until both col-
umns are completely disengaged. 2-11. INSPECTION.
k. Remove searchlight control and support
columns from helicopter.
i. Install plug buttons in helicopter floor and 2-12. Inspect components of searchlight system
lower skin holes, if required. in accordance with the following:
m. Lower helicopter with jacks or hoist as a. Inspect searchlight upper control and lower
specified in HMI Vol 1. support columns for deformation and damage.
Inspect inner shaft ends within columns for dry-
2-10. ELECTRICAL COMPONENTS. ness (lack of lubrication). Inspect lower support
column for corrosion.
plate support at bottom of fuselage (fig. 2-1) as b. Inspection condition of wiring on search-
follows: light upper column, coiled cable on extendable
(1) Tag and disconnect wiring, jumper support column, and wiring connectors at dual
wires, IN5401 diode, and bus (with 1/2 RNF-100 lights.
sleeve) from relay terminals. c. Inspect slidelock pin for deformation.
(2) Remove screws and washers from nut- Verify pin has adequate setscrew retaining
plate support, and remove relays. hole.
2-3
2-13. REPAIR b. Hoist

or jack up helicopter as specified in
HMI Vol 1 until landing gear skids or floats are
2. 14. Repair of searchlight system is limited to approximately 2 feet above ground.
replacement of defective or damaged parts as c. Engage lower support column into end of
follows: upper control column (fig. 2-1). Make certain
a. Replace deformed
or damaged upper con- that slidelock pin attachment hole on support col-
trol and lower support columns on searchlight. umn is aligned with control column handle during
Apply thin coating of grease (6, table 3-1) on installation (handle and hole should face aft).
inner shaft ends within control columns, if shafts i.
While installing lower support column, twist
are dry. Spray lower support column with dry grip on control handle until key on upper internal
lubricant (5. table 3-1). shaft tin control column) engages keyway on lower
Replace damaged or frayed wiring and internal shaft tin support columnj.
connectors. e. Hold searchlight in assembled position and
c. Replace deformed slidelock pin. If neces- have helicopter lowered to ground with jacks or
sary, enlarge setscrew retaining hole on slidelock hoist as specified in HMI Vol 1.
pin. Position upper bearing plate so that lock slot
faces aft, and secure plate to floor pan with bolts
2-15. INSTALLATION OF SEARCHLIGHT (19, fig. 1-1).
COMPONENTS.
g. Assemble slidelockhousing, spring, and
pin (fig. 2-1). Compress and hold spring com-
2-16. ELECTRICAL COMPONENTS. pressed, with a suitable tool so that attachment
a. Install SEARCHLIGHT ON-OFF switch end of pin protrudes from housing.
(fig. 2-1) on control column as follows: h. Insert slidelock pin through slot on control
(1) Connect wiring and install switch in column and into hole near top of support column.
housing. Tighten setscrew on top of support column making
(2) Install housing on control column and certain that retaining hole in slidelock pin is
secure with screws. engaged. Remove tool used to compress housing
b. Install SEARCHLIGHT PWR and CONT cir- spring.
cult breakers (25, 26, fig. 1-1) and EXT caution i. Check mechanical operation of searchlight
light assembly (27, 28) on lower switch and cir- by extending, rotating, tilting, retracting, and
cult breaker panel as follows: stowing unit. If excessive friction is evident,
(1) Install SEARCHLIGHT EXT caution spray lower support column with dry lubricant
light assembly on panel and connect wiring to (5, table 3-1).
light assembly. Zf required, replace lamp in Check that external wiring cable is properly
light assembly cap on face of panel, wrapped around support column; then route cable
(2) Install SEARCHLIGHT PWR and CONT through access holes in lower fuselage skin and
circuit breakers on panel and connect wiring to searchlight lower support (69, fig. 1-1).
circuit breakers, k. Install seal (48) and clamp (47) on support
(3) Install and secure lower switch and (7Sj to retain external wiring cable.
circuit breaker panel to instrument panel with Connect wiring at splices SP66 and SP67,
screws (HMI Vol 1). ground terminal E27, and relays K302 and K303.
Install relays K302 and K303
c. on nutplate (For detailed wiring instructions, refer to para-
support at bottom of fuselage (fig. 2-1) as graph 3-15.
follows: m. Verify that caution decal (18, fig. 1-1) is
(1) Using screws and washers, install attached to forward side of control column just
relays on nutplate support. below switch housing.
Install bus (with 1/2 RNF-100 sleeve),
(2) n. Verify that light switch ON-OFF decal is
IN5401 diode, jumper wires, and wiring to relay att;iched to top of control column just forward of
terminals. handle.
o. Perform operational check of searchlight
2-17. SEARCHLIGHT ASSEMBLY. system (para 2-6).
a. Place searchlighf-~ontrolcolumn (fig. 2-1)
2-18. REPLACEMENT OF SEARCHLIGHT
in floor pan, and allow control column to extend
LAMP.
through lower bearing plate and support at bottom
of fuselage. Do not install bolts (19, fig. 1-1) at 2-19. Refer to figure 1-1 and remove and replace
this time. searchlight lamp as follows:
2-4
E) Huahes Helicopters
REFERENCE SHEET
SERVICE INFORMATION NOTICES AND LETTERS
Action Reference
When performing maintenance or inspection of Manually Operated Searchlight

refer to Service Information Notice No. DN-50
system electrical components,
for installation ofvoltage transient suppressors to prevent voltage spikes
from damaging the reversing circuitry of lateral and longitudinal trim actuator
assemblies.
HMI Reference
Insert this sheet in Manually Operated Searchlight kit maintenance instruc-
tions No. CSP-032, Section 2, page 2-5.
This reference sheet shall be kept as part of the manual until the data is
incorporated at the next revision of CSP-032.
a. Remove screws from lens ring and remove d. Install lens ring and secure to lamp housing
ring from lamp housing (24). (24~jwith screws.
b. Lift sealed beam lamp (23) from housing
(247 and remove screws from wire terminals at
backoflamp. Remwelamp. 2-20. WIRING DIAGRAM.
Install replacement lamp
c. by connecting wire
terminals in housing to back of lamp, and secure
wiring to lamp with screws. Position lamp (23) 2-21. See iigure 2-2 ~or the searchlight system
in housing (24). wiring diagram.
BUS
W3 DS401(LH)
CB 127
Al- I A2
BLACK
4~---- P506AE
1035 AL557A1
DS402(RH)
Al
I
A2
GRAY-~P-6REEN
K3D2 I K303 i
X2 rtr X2
E27
CR4
IN5401f I_IX1
X1
JUMPERS AWG 20
L563A 16-YEL
S3 CB 128
SP66 OFF
1-, 2 1~7 2
3, P50bX10 ~--K51*16
5A
2o--~--LS"A16 2
KEY SWITCH 5205
CAUTION LIGHT I ~JUMPER AWG 20 SEARCHLIGHT

(PRESS TO TESTI
NOTES: /C1 XDS" SP67
2 L562820 L510C20-WHi
1. SOLIDIINES I--1 INDICATE
S206
WIRING OR ITEM SUPPLIED WITH \(3
SEARCHLIGHT KIT. 1, SEARCHLIGHT
1565A20N STOWED
2. DASHED LINES --I INOICATE
WIRING OR ITEM OF HELICOPTER E3
ELECTR ICAL SYSTEM (SECTION 19.
HMI-VOLI). 47-294
Figure 2-2. Searchlight wiring diagram
2-5/2-6
SECTION 3
INSTAUATION INSTRUCTIONS
3-1. GENERAL INFORMATION. 3-3. REFERENCE DATA. Referenceis made

in the instructions to applicable data in HMI Vol 1
3-2. SCOPE. Procedures inthis section maybe required for the searchlight installation. Table
performed at the operators discretion and are 3-1 lists consumable materials and expendable
applicableto all 369D helicopters. These instruc- items as well as electrical components required
tions provide for the installation of the manually for installation of the complete searchlight kit.
operated searchlight kit and include modifications Items listed are recommended items of a com-
to the right side pilots floor compartment, floor, mercial nature which may be procured locally.
and structure. Alternate, but equivalent, items are acceptable.
Item Commercial Product(Z)

No. Material Specification No.(l) Name/No. Manufacturer
1 Primer, zinc MIL-P-8585 (3)

chromate
2 Sealing compound MIL-S-7502 PR-1221 Product Research

Burbank, California
3 Adhesive EC 1751 3M Co.

St. Paul, Minnesota
4 Sealant EC 800 3M Co.

St. Paul, Minnesota
5 Dry lubricant MZL-L-46010A Ecoalube Everlube Corp.

No. 642 North Hollywood
California
6 Grease, aircraft MIL-G-23827 Brazcote 627 Brat Oil Company

and instrument Aero Shell 7 Shell Oil Company
Exxon 5114EP Exxon Company
7 Tape, double E-706 Arno Adhesive Tapes,

faced Inc.
Los Angeles, California
8 Tie strap, nylon MS17821-1-9 Ty-Rap
9 Solder, tin alloy QQ- S-571 (3)

(composition
SNGOWRPP)
10 Wire, electrical, MIL-W-16878 Standard Wire and Cable

El Segundo, California
10-gage ~pe EE, AWG-10,
single conductor
3-1
Section 3 Opt Eqpt Ma.nual CSP-032
Table 3-1. Consumable materials and expendable items (cont)
Item Commercial Product(a)

No. Material Specification No. (1) Name/No. Manufacturer

Is-gage Type EE, AWG-16, El Segundo, California
single conductor

20-gage Type EE, AWG-80, El Segundo, California
single conductor
13 Sleeving, RNF-100 Transparent Products

termofit, Los Angeles. California
1/2-inch, black
14 Sleeving, RNF- 100 Transparent Products

termofit, Los Angeles, California
1/4-inch, black
15 Sleeving, tube, MIL-I-631 Transparent Products

1/4-inch, clear Type F, Form U, Los Angeles, California
Grade ii, Class i,
Category 1
16 Splice, knife 32445 Rayclad

(SP66, SP67) Redwood City, California
24 Diode (CR4) IN5 401
25 Cap, electrical, PD Type 1 Rayclad

3/8-inch Redwood City, California
26 Covering Aeromat 31 RNS John Schneller and
(carpeting) Color 351/381 Associates
Kent, Ohio
NOTES: (1) Numbers are U. S. A. Specifications and Standards. The prefix symbols are defined as
follows: AMS American Material Standard; MS Military Standard; MIL- Military
Specification; Single, double or triple alpha prefix of the same letter Federal Specifi-
thesame type with the listed Specification No. cannot be determined.
3-2
3-4. PREPARATION FOR INSTALLATION. NOTES:
Use Cleco clamps and fasteners as required to

kit includes the following: facilitate rivet installation, and install rivets
a. Check all electrical switches for OFF posi-
with wet zinc chromate primer (1, table 3-1).
tion, and ensure that BATTERY-OFF-EXT
switch is at OFF. Rivets are equally spaced and are normally

b. Identify all components, including attaching positionedtwice the diameter of the rivet shank
hardware, to be removed for access to work from the outside edge of the material, edge of
areas. Protect components from damage and joggle, or flange radius.
foreign matter until reinstalled. When providing ground or electrical components,
clean surface structure to bare metal.
3-5. REMOVAL OF HELICOPTER EQUIPMENT.
Do not tighten electrical clamps or secure elec-
3-6. Prior to installing the searchlight kit, a trical wiring to existing harnesses until all
limited number of items must be removed from electrical wiring is installed.
the helicopter to accommodate kit installation.
3-11. STOWAGE COMPARTMENT LOWER
Refer to HMI Vol 1 and perform the following:
Remove seat from right side of crew
SUPPORT.
a.
compartment. a. Position doubler (80, fig. 1-1)

on outer ship
b. Remove copilots cyclic stick, if installed. skin to match cutout as figure 3-1. Use
shown in
c, Remove floor access door and attached doubler (80, fig. 1-1) as template, and determine
carpeting from pilots right side floor 29 rivet hole locations required through ship
compartment. skin. Using drill motor and appropriate drill
d. Remove stowage box from pilots right bit, drill twenty O. 098-inch diameter rivet attach
sid~efloor compartment. holes around circumference of doubler and nine
0. 098-inch diameter holes around circumference
3-7. MODIFICATION OF HELICOPTER. of cutout. Attach doubler (80) to skin with rivets
(72).
3-8. Modification of the helicopter (fig. 3-1)
consists of providing an access port for the NOTE: Doubler (80) is provided with a 2. 50-
searchlight assembly through the lower ship skin inch diameter cutout, 29 rivet attach holes,
in the pilots right side floor compartment as and a drain hole cutout.
follows:
a. Locate longitudinal support in substructure b. Using drill motor and appropriate drill bit,
of pilots floor compartment at BL 13. 00 RH, drill 0. 180-inch diameter drain hole in ship skin
between the aft bulkhead at canted station 64. 365 to match doubler (fig. 3-1).
and the floor compartment frame at station 50. 50. c. Position channels (78, 79, fig. 1-1) over
Remove rivets from support using drill motor existing rivet attach holes in ship skin, eompart-
and appropriate drillbit, and remove support. ment frame, and aft bulkhead. Channel (79)
b. Locate and mark hole center for cutout in should abut cutout in ship skin, and channel (78)
ship skin. Center of cutout is located at BL should be 3 inches outboard of channel (79). Using
12. 75 RH and station 52. 36 (1. 86 inches aft of drill motor and appropriate drillbit, drill 0. 098-
floor compartment frame). inch diameter rivet attach holes through channels
c. Using chassis punch or equivalent, cut (78, 79) and doubler (80) as shown in figure 3-1.
2.~0-inch diameter hole in ship skin as shown. Attach channels (78, 79, fig. 1-1) to frame, bulk-
head, and doubler (80) with rivets (72).
3-9. INSTALLATION OF SEARCHLIGHT KIT.
NOTE: Do not install rivets through attach
3-10. searchlight kit includes
Installation of the holes required for securing support (77) to
procedures for installing the searchlight upper channels (78, 79) at this time.
and lower supports on the: right side of the pilots
floor compartment, caution light and circuit i. Using existing holes in compartment frame
breakers on the instrument panel, the searchlight astemplate, drill four additional O. 098-inch
assembly and associated electrical wiring, and diameter rivet attach holes through doubler (80),
the access cover on the right side pilots floor and secure doubler to frame with rivets (72) as
compartment. The general notes that apply to shown in figure 3-1.

the subsequent installation procedures are as e, Position support (77, fig. 1-1) over exist-
follows: ing rivet holes in channels (78, 79), and against
3-3
NOTE:
LONGITUDINAL SUPPORT IN PILOTS RIGHT

SIDE FLOOR COMPARTMENT IS REMOVED TO
PERMITCUTOVTINSKINFORSEARCHLlcHT
INSTALLATION. EXISTING RIVET A~ACH
HOLES ARE USED FOR ATTACHMENT OF
SEARCHLIGHT LOWER SUPPORT.
LONGITUDINAL
SUPPORT (NOTE)
FLOOR
FLOOR ACCESS
COM PA RTMENT I O
FRAME
I Do
\o
RBL
o cc
500-A SEARCHLIGHT
oousLEq
CENTER OF 2. 50-INCH
jMATCH I I DIAMETER CUTOUT

IN SKIN TO
TUOCRELBD EXISTING FLOOR
COMPARTMENT FRAME
AFT
P
FWD
BULKHEAD
II f \I
--1
INBD
Ii I I I Ii f f
t- i. 86 INCHES
I i cI+I
TRUE
PILOTS RIGHT SID~
O FLOOR COM PA RTMENT
t
II I i/
i;
CENTER OF 4 11
25
INCHES
Iii I j-/ CHAFF
DOUBLER
iiI+lj f
STRIP
II
II jl t +~\DRAIN HOLE
I
II ~e
j
II 4;1
L i
EXISTING I+
LOWER SUPPORT
CHANNEL
3. 00 INCHES --~-II
RH CHANNEL~I 3 Ii I,,LH CHANNEL
t,,,,
Q DOUBLER ALIGNMENT (LOOKING UP)
47-297
Figure 3-1. Doubler and lower support attachments
3-4
compartment frame. Drill four O. 098-inch m. Using screws (55) and washers (56), attach
diameter rivet attach holes in support (77) for relays (57) to support (65).
attachment to channels, and five O. 098-inch n. Attach bus (54) with 1/2-inch RNF-100
diameter rivet attach holes for attachment to sleeving (13, table 3-1) to terminals K302-A1 and
frame as shown in figure 3-1. Attach support K3031A1 on relays (57, fig. 1-1). For detailed
(77, fig. 1-1) to frame, channels (78, 79), wiring instructions, refer to paragraph 3-15.
doubler (80), and ship skin with rivets (72). o. Attach diode (24, table 3-1) to terminals
f. Position angles (75, 76) on channels (78, 79) K3-~2-X1 and K302-X2 on relay (57, fig. 1-i).
against compartment frame. Drill six 0. 098-inch For detailed wiring instructions, refer to para-
diameter rivet attach holes through angles and graph 3-15.
frame. Attach angles (75, 76) to frame with E Using adhesive (3, table 3-1), bond chafe
rivets (72). strip (53, fig. 1-1) to bracket (74) as shown in
g. Position bracket (74) in channel (79), figure 3-1.
angle (76), and support (77). Drill four 0. 098- q. Usingbolts(49, fig. 1-1), washers(50)
inch diameter rivet attach holes through channel and nuts (51), attach bearing plate (52) to support
(79) and bracket (74), and one 0. 098-inch diameter (77).
rivet attach hole through top of support (77) and r. Using screws(45), andwashers(46), attach
bracket(74), Drill additional two 0. 1285-inch clamp halves (47) and seal (48) to support (77).
diameter rivet attach holes through angle (76), Install bolts (42), washers (43) and nuts (44) in
channel (79), and bracket (74). Attach bracket clamp halves (47) but do not tighten bolts at this
(74) to channel (79) and support (77) with rivets time.
(71, 72). Also, attach bracket (74) to channel s. Using sealant(4, table 3-1), sealbox
(79) and angle (76) with rivets (70). formed by support(77), brackets (73, 74), and
h. Position bracket (73) in channel (78), angle compartment frame so that lower support is
(75~, and support (77). Drill from O. 098-inch watertight.
diameter rivet attach holes through channel (78)
and bracket (73), and one 0. 098-inch diameter NOTE: Do not cover clamp halves (47) or
rivet attach hole through top of support (77) and external wiring cable access hole with sealant.
bracket (73). Drill additional O. 1285-inch
diameter rivet attach hole through angle (75), 3-12. COMPARTMENT FLOOR AND UPPER
channel (78), and bracket (73). Attach bracket
(73) to channel (78) and support (77) with rivets a. Position channel (41, fig. 1-1) on existing
(71, 72). Also, attach bracket (73) to channel floor channels at pilots right side floor compart-
(78) and angle (75) with rivet (70). ment and determine attach hole locations for
Use support (77) as template and deter- channel (41), supporting angles (40), and filler
mine attach hole locations required for nutplates (39). Drill O. 098-inch diameter rivet attach holes
on bracket (74). Drill four O. 098-inch diameter as required and attach channel (41, fig. 1-1),
rivet attach holes through bracket (74). Attach angles (40), and filler (39) to existing floor chan-
two nutplates (68, 69) on bracket (74) and support nels with rivets (29).
(77) with rivets (67). Also, attach two nutplates
(69) on support (77) with rivets (67). NOTE: Make certain that filler (39) is posi-
i. Position angle (66) on channel (78) and tioned onleft side of channel (41) between angle
determine attach hole locations. Drill six 0. 098- (40) and existing channel.
inch diameter rivet attach holes through channel
and angle. Attach angle (66) to channel (78) with b. (37, 38) between existing
Position channels
rivets (63). floor channel forward side of pilots floor com-
on
k. Position nutplate support (65) on channel partment and channel (41), and determine attach
(i9~and angle (66) and determine attach hole hole locations for channels (37, 38) and support-
locations. Drill six 0. 1285-inch diameter rivet ingangles(34, 35, 36). Drill 0.098-inch dia-
attach holes through support and channel. Attach meter rivet attach holes asrequired and attach
support (65) to channel (79) with rivets (64). channels (37, 38) and angles (34, 35, 36) to
Also, drill four O. 098-inch diameter rivet attach channel (41) and existing floor channel with rivets
holes through support (65) and angle (66). Attach (29).
support (65) to angle (66) with rivets (63). c. Position web (33) with floor pan (32) on
i. Attach E27 ground stud screw (58), lock exrsting floor channels and on channels (37, 38,
washer (60), and jam nut (61) to support (65); 41), and determine attach hole locations. Drill
then place washers (59) on screw (58) and secure O. 098-inch diameter rivet attach holes as
washers with nut (62). required and attach web (33), pan (32), and straps
3-5
(30, 31) on floor channels and channels(37, 38, f, Attach terminal (12) to wire No. P506AE10
41) with rivets (29). (10; then connect wire with terminal to bus W3-4.
Attach terminal (22) to other end of wire; then
3-13. CIRCUIT BREAKERS AND CAUTION connect wire with terminal to circuit breaker
LIGHT. terminal CB127-1.
a. Remove attach screws from lower switch Attach terminal (23) to wire No. L557A10
and circuit breaker panel on instrument panel clo~:then connect wire with terminal to circuit
(HMI Vol 1). Pull out optional equipment panel breaker terminal CB127-2. Attach terminal (21)
and remove plug buttons from holes provided for to other end of wire; then connect wire with ter;
circuit breakers (25, 26, fig. 1-1) and caution minal to relay terminal K302-A1.
light assembly (27).
b. Install caution light assembly (27) and NOTE: Steps h through provide for wiring
lamp (28) in hole identified by decal marked installations between the relays and the relay
EXT-PRESS TO TEST. ground, and wiring from the searchlight assem-
c. Install circuit breaker (26) in hole identi- bly. (See fig. 2-2.
fled by decal marked CONT.
d. Install circuit breaker (25) in hole identi- Attach terminals (18) on two jumper wires
h.
fie~dby decal marked PWR. (12~;then connect one wire with terminals to
e. Connect electrical wiring on circuit break- relay terminals K302-X1 and K303-X1. Connect
ers and caution light assembly (para 3-15). remaining wire with terminals to relay terminals
f. Using attach screws, attach lower switch K302-X2 and K303-X2.
and circuit breaker panel to instrument panel i. Attach terminal (18) to jumper wire (12);
(HMI Vol 1). then connect wire with terminal to relay terminal
K303-2. Attach terminal (19) to other end of
3-14. SEARCHLIGHT ASSEMBLY. For installa- wire; then connect wire with terminal to E27
tion of searchlight assembly (22. fig. 1-1), ground stud.
including lamp (23) and lamp assembly (24), refer Connect wiring from searchlight assembly
to paragraph 2-15. as follows:
(1) If required, attach splice SP66-B (16)
3-15. ELECTRICAL WIRING. to wire No. L564A16 (yellow wire from 5205-1).
Connect yellow wire with splice to splice SP66-A
NOTE: Steps a through g provide for wiring ton wire from circuit breaker).
installations from the W3 bus to the circuit (2) If required, attach splice SP67-B (16)
breakers, relay terminal K302-A1, caution to wire No. L562A20 (white wire from S206-2).
light and ground, and splices SP66 and SP67 Connect white wire with splice to splice SP67-A
(see figure 2-2). ton wire from caution light).
(3) If required attach terminal (19) to wire
a. Attach terminals (22, table 3-1) to wire No. L510G20 (white wire from S206-1). Connect
No, K510F16 (11); then connect wire to circuit white wire withsplice to E27 ground stud.
breaker terminal CB128-1 and key switch ter- (4)
required, attach terminal (20) to
If
minal S3-2. wire No. L563A16 (yellow wire from S205-2).
b. Attach terminal (17) to one end of jumper Connect yellow wire with terminal to relay ter-
wiFe (12); then connect wire with terminal to minal K302-X1.
circuit breaker terminal CB128-2. Attach (5) If required, attach terminals (21) to
other end of wire to caution light terminal red and green wires from lamps (red wire from
XDS11-1 and with solder (9).
secure DS401-2 and green wire from DS402-2). Connect
c. Attach wire No. L562B20 to caution light green and red wires with terminals to E27 ground
ter~minal XDS11-8 and secure with solder (9). stud.
Attach splice SP67-A (16) to other end of wire
for eventual connection to searchlight wiring. NOTE: U required, terminals (21) are used
d. Attach terminal (17) to wire No. L564B20 on ends of red and green wires at lamp ter-
(1ZI; then connect wire with terminal to circuit minals DS401-2 and DS402-2.
breaker terminal CB128-2. Attach splice
SP66-A (16) to other end of wire for eventual (6) If required, attach terminals (21) to
connection to searchlight wiring. black and gray wires from lamps (black wire
e. Attach terminal (17) to wire No. L565A20N from DS401-1 and gray wire from DS402-1). Con-
(12~; then connect wire With terminal to ground nect black wire with terminal to relay terminal
stud E3. Attach other end of wire to caution K302-A2; connect gray wire with terminal to relay
light terminal XDS11-3 and secure with terminalK303-A2. Cover relay terminals with
solder (9). caps (25).
3-6
NOTE: If required, terminals (23) are used f. Drill two each O. 098-inch diameter holes
onends of black and gray wires at lamp ter- inchannel (41) for retention of springs (3).
minals DS401-1 and DS402-1. Attach springs (3) to channel (41) with rivets
(4). Using grommets (2), secure corresponding
Install protective sleeving (15) over
(7) studs (1) to access cover (16).
SP66 and SP67 splice connections and secure g. Install access cover (16) and secure fas-
wiring with tie straps (8). tener studs (1, 5, 10) to fastener
retaining
springs (3, 8, 12) on floor compartment.
3-16. ACCESS COVER. Check cover for proper fit and security of
a. P~onaccesscover (16, fig. 1-1) on fasteners.
exrsting floor channels and channel (41), and 1. Using double-faced tape (7, table 3-1),
determine attach hole locations for fastener install floor carpeting (26); cut and trim carpet-
studs in cover (16), channel(41), and floor ing to accommodate searchlight base, access
channels; locate from pilot holes provided in cover(ls, fig. 1-1), andweb(3).
cover (16). Using drill motor and appropriate
drillbit, drill O. 218-inch diameter holes for
3-17. INSTALLATION OF HELICOPTER
fastener studs in cover (16), channel(41), and
EQUIPMENT.
floor.
b. Drill O. 218-inch diameter hole in each of
three angles (15) for location of fastener retainer 3-18. After installation of searchlight kit, a
springs. limited number of items must be replaced in the
c. Position angles (15) on floor access aft helicopter. Refer to HMI Vol 1 and perform
channel and determine angle attach hole locations. the following:
Drill O. 1285-inch diameter rivet attach holes, a. Install seat on right side of crew
two in each angle (six in floor channels). Attach compartment.
angles (15) to floor channel with rivets (14). b. If searchlight assembly is removed from
Drill two each O. 098-inch diameter holes
d. heTicopter (para 2-9), install copilots cyclic
inangles (15) for retention of springs (12). stick as required.
Attach springs (12) to angles (15) with rivets
(13). Using grommets (11), secure correspond- 3-19. WEIGHT AND BALANCE DATA.
ing studs (10) to access cover (16).
e. Drill two each O. 098-inch diameter holes
in floor access side channels for retention of 3-20. Weight and balance data resulting from
fillers (7) and springs (8). Attach fillers (7) and installation ofsearchlight kit is listed in
springs (8) to channels with rivets (9). Using table 3-2. After installation of kit, incorpo-
grommets (6), secure corresponding studs (5) rate changes in helicopter weight and balance
to access cover (16). records as instructed in HMI Vol 2.
-501I(it
(complete)
Added 18.2 52.0 946
Removed 4. 3 53. 0 227
Changed 13.9 51.7 719
-501 Kit
(without 500-A
searchlight assembly)
Added 6. 3 52. 8 333
Removed 4. 3 53. 0 227
Changed 2.0 53.0 106
3-7/3-8
CSP
033
Illustrated Parts list

and
FOR
PUBLIC ADDRESS AND SIREN SYSTEM INSTALLATION
Part No. 369B90143
Hughes Halicopters aa,~ rwaa/rul,s axranmM
COD775121 Issued 1 January 1978

IVI FG I
INTRO
INSEIIT IATESI CHANGED PAGES, DESTROY SUPEISEDLD PAGES.

LIST OF EFFECTIVE PAGES THE ASTERISK INDICATES PAGES CHANGED. ADDED. OR DELETED BY THE CURRENT CHANGE.
Title Original F-l Original

A thru B Original F-2 Blank Original
CBlank Original 1-1 thru 1-4............. Original
i Original 2-1 thru 2-6 Original
CSP-033
Opt Eqpt Manual
HUGHES TECHNICAL MANUAL RECOMMENDED CHANGE REPORT
revisions.
Hughes Helicopters
Culver City, Calif6mia 90230

2T17B
Originator
Address
Figure Number(s)
Etemarks/Recommendations
B/C
RECORD OF REVISIONS
CSP-033
MFG REV

TABLE OF CONTENTS
Section Page
FOREWORD F-l

of this Manual F-l
F-3. Applicability F-1,
Combined Optional
Equipment.......... F-l
Contents F-l
Related Publications.... F-l
and Revisions F-l
1-1. Scope and Contents..... 1-1

1-3. Group Assembly
Parts List 1-1
2 MAINTENANCE INSTRUCTIONS.. 2.-1

2-6. Operational Check..... 2-1
2-8. Replacement of System
Components. 2-1
2-16. Repair 2-6

Equipment.......... 3-2
3-7. Modification of
Helicopter 3-2
3-9. Installation of System
Components......... 3-2
3-16. Installation of Heli-
copter Equipment 3-6
3-18. Weight and Balance
Data.............. 3-6
FOREWORD
tained in HMI Vol 1 and 369D IPC, and presented in sequence as defined in section i,
contains instructions for initial installation and HMI Vol i.

continuing maintenance of the public address and
siren system. Weight and balance data is F-9. USE OF THIS MANUAL.
for procuring replacement parts for the system F-10. This manual is for use by operators of the
equipment. Model 369D helicopter equipped with the public
address and siren system. Although this manual
F-3. APPLICABILITY. is a separate publication, it should be kept with
HMI Vol i, HMI Vo12, 369D IPC, and other
F-4. The public address and siren system is handbooks listed in section 1, HMI Vol 1 that
applicable for use on any Hughes 500D and 500MD form the primary information file for the
(Model 369D) helicopter. helicopter.
F-5. COMPATIBILITY OF COMBINED F-ll. RELATED PUBLICATIONS.

OPTIONAL EQUIPMENT.
F-6. For compatibility information on which of HMI Vol 1, 369D IPC, and applicable
optional equipment may or may not be used in Opt Eqpt Manuals as required to accomplish
combination at the same time, refer to section 21, instructions contained herein.
HMI- Vol i.
F-8. The contents of this manual are grouped manual are made as defined in section 1, HMI
F-1/F-2
SECTION 1
1-2. This illustrated partsprovides, by

list 1-6. Isometric illustrations are provided for
means of text (parts lists)companion illustra-
and each group assembly parts list. Each illustration
tions, a complete parts definition of the public is exposed to the extent necessary to show parts
address and siren system manufactured by Hughes relationship for the public address and siren
Helicopters, Culver City, California. system installation.
NOTE: The illustrated parts list is organized 1-7. USABLE ON CODE.

and presented on the same manner as the 369D
Series Illustrated Parts List (3691) IPC). 1-8. The USABLE ON CODE column located at
(For information on use, refer to 369D IPC.) the right-hand side of the Group Assembly Parts
List pages indicates the effectivity of parts by air-
1-3. GROUP ASSEMBLY PARTS LIST. craft serialnumber. In many cases two different
parts are listed, one representing the original
1-4. Theparts lists furnish information for pro- installation and another representing an improved
replacement item. Alphabetic codes are used to
curing replacement parts for the public address
and siren system, and shall not be used for any indicate the aircraft serial number applications
other purpose. For information or procurement of a given part. When no USABLE ON CODE is
of other replacement parts, refer to 369D IPC. listed, items are understood to have full effectivity.
1-1
FIG. UNITS USABLE

NO. NO. ASSY CODE
1 -1 3 69 H9 01 43 501 PUBLIC ADDRESS AND SIREN SYSTEM I REF

INSTALLATION KIT
-1 3691190143-17 WIRE HARNESS ASSEMBLY 1
-2 369 H90143 -1 5 1 WIRE HARNESS ASSEMBLY I 1
-3 369H90143-19 1 WIRE HARNESSASSEMBLY 1
-4 MS2 5244-2 5 CIRCUIT BREAKER(CB 129) 1
-6 AN960-8L WASHER 2
-7 MS21042 -08 1 NUT 2
-8 CM88B I MICROPHONE AND HOLDER 1
-9 RMC-1S-A I CONTROL UNIT 1
-10 NAS1218-06-2 SCREW 4
-11 AN960P06L I WASHER 4
-12 369B90143-23 SUPPORT I 1
-13 MS35489-15S I GROMMET 1 1
-14 MS20470B3 RIVET 1 8
-15 NAS697C06LM I NUTFLATE 1 4
-16 NAS623-3-3 1 SCREW 4
-17 AN960PD10 WASHER 4
-18 MS21042-3 1 NUT 2
-19 MS20470AD4 I RIVE T 8
-20 3691190143-31 BRACKET ASSEMBLY 1
-21 369H90143-41 BRACKET ASSEMBLY 1
-22 MS2B171-1S NIPPLE 4
-23 369H90143-21 1 LOUDSPEAKER ASSEMBLY 1
-24 MS3 5489 -16 1 GROMMET I 1
-25 MS20470AD3-3 RIVET 1 6
-26 369H90143-27 1 DOUBLER 1
-27 AN935-416L WASHER 8
-28 MA-500 I AMPLIFIER I 1
-29 NAS1403-3 SCREW 4
-30 NASS 60PD10 I WASHER 4
-31 369B90143-3 SUPPORT 1 4
-32 NAS1403-3 I SCREW 8
-34 MS21042-3 I NUT 8
-35 369H90143-11 1 CHANNEL ASSEMBLY I 1
-36 NAS1403-3 I SCREW 4
-37 AN9 60PD10 WASHER 4
-38 369B90137-3 1 FORWARD SUPPORT 1 1
-39 369B90137-4 AFT SUPPORT i 1
-40 MS20470AD3 I RIVET 1 44
-41 369A2515-27 SUPPORT CHANNEL I 1
-42 MS20426AD3 I RIVET 1 4
-43 NAS686A3K NUTPLATE 2
-44 NAS1329C3-8 RIVNUT 1 2
1-2
Section 1
INOTE !I 6
(NOTE
2)b
13
.d 12
11
15 9
o----
~i Ilo INSTRUMENT PANEL
o
~b
NOTES:
LOWER CIRCUIT BREAKER
i. MICROPHONE AND HOLDER ARE PROVI DED
AND SWITCH PANEL
AS A UNIT.
2. ATTACHMENT SCREWS ARE SUPPLIED

WITH CONTROL UNIT.
p
3. ATTACHMENT BOLTS ARE SUPPLIED WITH
O
AMPLIFIER.
4. EXISTING RIVET HOLES.
47-298-1
Figure 1-1. Public address and siren system installation kit (sheet 1 of 2)
1-3
17, \t_ ,STA.43.M)
WL 22. 00
RH FLOOR
LONG~RON ii FLOOR
OOo oU INTERCPSTAL
STA 50. 50
(NOTE 4)
IB; 3~ 3
II/ STA 44. 65

(NOTE 4) 1/ 4~
is
17,
26
22 k:
23
LOUDSPEAKER
AND BRACKET
20 di~
~t" I
I
3
40
.j
I
SUPPORT
I
AMPLIFIER~7
CHANNEL
O 2d
41
SUPPORTS, AND
CHANNELS
\IY
o 47-298-2
Figure 1-i. Public address~ and siren system installation kit (sheet 2 of 2)
1-4
SECTION 2
2-1. GENERAL INFORMATION. b. On control unit panel, place selector knob

for public address system at position. on
2-2. DESCRIPTION. The public address and c. Using microphone removed from top of
siren system provides the helicopter with an inte- controlunit, check operation of public address
gral airborne installation consisting of an audio system. Position selector knob as required for
amplifier, two loudspeakers, a remote control desired audio control.
unit, microphone, system circuit breaker, three d. Verify that both loudspeakers are in
interconnecting wire harness assemblies, operation.
miscellaneous electricalwiring, and brackets e. Place siren selector knob in on position,
and attachment hardware (fig. 1-1). All three check siren operation in yelp or curdler positions
wire harness assemblies are attached to the audio on adjacent selector knob; then place siren selec-
amplifier; one assembly provides de power to the tor knob in off position.
amplifier, and the remaining two assemblies f.

Place selector knob for public address
provide de power from the amplifier to the con- system at off position.Stow microphone on top
trol unit and loudspeakers. The amplifier is of control unit.
installed in the lower electronics compartment g. Place BATTERY-OFF-EXT PWR switch at
under the pilots compartment floor. The OFF position.
loudspeakers are attached to a bracket on the
exterior of the fuselage, just forward and below 2-8. REPLACEMENT OF SYSTEM COMPONENTS.
the door on the right side of the pilots compart-
ment. The remote control unit is mounted on the 2-9. AMPLIFIER.
upper right side of the instrument panel for access a. Verify BATTERY-OFF-EXT PWR switch at
by both the pilot and copilot. The microphone is OFF position.
attached to a holder on top of the remote control b. Open floor access door on left side of pilots
unit support. compartment for access to electronics compart-
ment and amplifier, as specified in section 2,
2-3. REFERENCEDATA. Informationpertain- HMI- Vol 1.
ing to
helicopter structural components which Disconnect wire harness assemblies
c. (1, 2,
interface with the public address and siren system 3, fig. 1-1) from amplifier at connectors P558,
installation is in the Structural Repair Manual
P559, and P560 (para 2-18).
(369D SRM). Information pertaining to standard d. remove four screws (29) and
Loosen and
helicopter equipment is in HMI Vol 1 and washers (30) from amplifier support (31). Remove
369D IPC. amplifier (28) and attached supports (31) from
channel assembly (35) in compartment.
2-4. TROUBLESHOOTING. e. Prepare replacement amplifier as follows:
2-5. Use information provided in table 2-1 for NOTE: A good structural electrical bond
troubleshooting the public address and siren (ground) must exist between amplifier (28)
system installation. and channel assembly (35) mounted in elec-
tronics compartment (refer to section 19,
2-6. OPERATIONAL CHECK. HMI Vol 1).
2-7. With helicopter on ground, perform opera; (1) (27) securing
Remove bolts and washers
tional check of public address and siren system supports (31) on amplifier (28). Discard
removed
as follows: bolts and washers (27) but retain supports (31) for
a. Place BATTERY-OFF-EXT PWR switch at installation.
BATTERY position. Verify PA SYS circuit (2)
Remove and discard supports provided
breaker on lower circuit breaker and switch panel on replacement amplifier. Retain bolts and
is engaged, washers (27) for installation.
2-1
Table 2-1. Troubleshooting public address and siren system
Electrical de power No de power on helicopter main bus. Refer to section 19, HMI Vol 1.
not available when
system turned on. Disconnected or defective system Connect or replace circuit breaker,
circuit breaker. as required.
Fuse blown at amplifier. Replace fuse at amplifier.
Disconnected or defective wire Connect or replace wire harness

harness between circuit breaker between circuit breaker and amplifier.
and amplifier.
Amplifier defective. Replace amplifier.
Circuit breaker trips. Overload or short circuit in system In turn, check loudspeakers, control
equipment. unit, and amplifier for short circuits;
also check electrical bond connections
(ground) at control unit and amplifier.
No audio when public Microphone disconnected or defective. Connect or replace microphone.

address position is
selected on control Defective circuits in control unit, Replace control unit.
unit
Disconnected or defective wire Connect orreplace wire harness
harness between amplifier and between amplifier and control unit.
control unit.
No audio when siren Defective siren circuits in amplifier. Replace amplifier.

position is selected
on control unit. Defective circuits in control unit. Replace control unit.
Disconnected or defective wire Connect orreplace wire harness

harness between amplifier and between amplifier and control unit.
control unit.
No audio at Disconnected terminals at Connect terminals at loudspeaker(s).

loudspeaker(s). loudspeaker(s).
Damaged loudspeaker(s). Repair or replace loudspeaker(s).
(3) Install supports (31) retained from 2-10. LOUDSPEAKERS.

removed amplifier and secure to replacement a. Verify BATTERY-OFF-EXT PWR switch
amplifier (28) with new bolts and washers (27). at OFF position.
(4) Check and make certain that 15-ampere b. Disconnect wire harness assembly (3) from
fuse is installed in amplifier (28). loudspeaker at drive unit (fig. 2-1 and para 2-18).
f. Install amplifier (28) in electronics com- c. Loosen and remove setscrew securing horn
partment and secure amplifier (28) and attached nut to threaded end of horn (fig. 2-1).
support;s (31) to c;hannel assembly (35) with d. Loosen horn nut, and
remove driver unit,
washers (30) and screws: (29). horn, and spacers from
mounting bracket.
g. Connect wire harness assemblies (1, 2, 3) e. Repeatsteps bthrough d for removal of
to amplifier at connectors P558, P559, and P560 remaining loudspeaker assembly.
(para 2-18). f, Install threaded endof horn through attachi
h. Perform operationalcheck of system ment hole in mounting bracket; then attach driver
(para 2-6). unit and spacers to threaded end of horn.
i. Close and floor door left
secure access on
g. Position driver unit as required and secure
side of pilots compartment. to mounting bracket with horn nut.
2-i
CSP-033
NOTES:
i. HORN NUT IS NORMALLY SCREWED

DOWN AND RETAINED ON HORN
CASTING THREADS.
2. A MAXIMUM OF THREE SPACERS

ARE REQUIRED.
3. GROMMET SEALS 0.85 INCH

DIAMETER HOLE IN HELICOPTER
SKIN.
WIRE HARNESS
GROMMET (NOTE 31
ol( 1(/ DOUBLER
k;ji
LOUDSPEAKER
ASSEMBLY INSTALLED
/4 n,\,!i:inv:r,
ii
i
NIPPLES
NUT
WASHER
TERMINAL
MOUNTING BRACKET I ELECTR I CAL

CONNECTORS
DRIVER UNIT
MS18063-23
SETSCREW
HORN NUT (NOTE 1) \S PACERS (NOTE 2)
HORN
O LOUDSPEAKERS (LOOKING INBOARD)
47-303
Figure 2-1. Loudspeaker installation
2-3
4 If required, use drill motor and appropriate b. Remove PA SYS circuit breaker (4) from
drill bit to provide hole for setscrew in threaded lower switch and circuit breaker panel as follows:
end of horn as follows: (1) Remove screws and lower switch and
(1) Use horn nut as template. circuit breaker panel from instrument panel for
(2) Drill 0.1405-inch diameter hole in access to PA SYS circuit breaker (HMI Vol 1).
horn casting. (2) Tag and disconnect wiring from PA SYS
(3) Tap hole for
setscrew (fig. 2-1). circuit breaker at terminals CB129-1 and CB129-2;
Secure horn nut in place with setscrew. and remove circuit breaker from panel.
Using 0-50 inch-pound torque wrench, tighten c. Install PA SYS circuit breaker (4) on lower
setscrew to torque of 6 inch-pounds. switch and circuit breaker panel as follows:
Connect wire harness assembly (3, fig. 1-1) (1) Install PA SYS circuit breaker on panel
to loudspeaker at drive unit (fig. 2-1 and para and connect wiring to circuit breaker terminals
2-18). CB129-1 and CB129-2.
4 Perform operational check of system (2) Install and secure lower switch and
(para 2-6). circuit breaker panel to instrument panel with
screws (HMI- Vol 1).
2-11. CONTROL UNIT AND MICROPHONE. d. Perform operational check of system
a. Verify BATTERY-OFF-EXT PWRswitch (para 2-6).
at OFF position.
b. Remove microphone (8, fig. 1-1) from 2-13. ELECTRICAL WIRING. The electrical
holder, and disconnect microphone cord from aft wiring for the
public address and siren system
side of control unit at connector P562 (para 2-17). consists of a power input wire harness assembly
Retain microphone for installation. (2), control unit input wire harness assembly (1),
c. Disconnect wire harness assembly (1) from and loudspeaker output wire harness assembly (3).
aft side of control unit (9) at connector P561 Refer to figure 2-2 for detailed wiring diagram,
(para 2-17). assembly connectors, and individual wire and
Loosen and remove screws (1D) and washers
d. connector data.
(115from support (12). Remove support (12) and a. Verify BATTERY-OFF-EXT PWR switch
control unit (9) from right side fairing of instru- at -~FF position.
ment panel. b. Disconnect power input wire harness assem-
e. Prepare~replacement control unit as follows: bly(2, fig. 1-1) from amplifier at connector P558,
from PA SYS circuit breaker terminal CB129-2
NOTE: A good structural electrical bond (para 2-12), and from helicopter ground at TB6-4
(ground) must exist between control unit (9), (section 20, HMI Vol 1) as shown in figure 2-2.
support (12), and instrument console structure Disconnect nylon tie straps (2, table 3-1) and
(refer to section 19, HMI Vol I). remove wire harness assembly.
Disconnect control unit input wire harness
c.
(1) Remove screws securing support (12) assembly (1, fig. 1-1) from amplifier at connec-
on control unit (9). Discard screws, tor P559, and from control unit at connector P561
as shown in figure 2-2. Disconnect nylon tie straps
NOTE: Detached control unit support (12) (2, table 3-1) and remove wire harness assembly.
has attached microphone holder. d. Disconnect loudspeaker output wire harness
assembly (3, fig. 1-1) from amplifier at connector
(2) support (12) on replacement
Install P560, and loudspeaker connectors LS(DS)1 and
control unit (9), using screws supplied with unit. LS(DS)2 as shown in figure 2-2. Disconnect wire
f. Using washers (11) and screws (10), secure TD4A14 at loudspeaker connectors LS(DS)1-L1
control unit (9) and support (12) to right side and LS(DS)2-L2. Disconnect nylon tie straps (2,
fairing on instrument panel structure. table 3-1) and remove wire harness assembly.
g. Connect wiring harness assembly (1) to aft e. Install wire harness assemblies (1, 2, 3,
side of control unit (9) at connector P561 (para fig. 1-1) in reverse order of removal, steps b
2-17). through d, and secure as required with nylon tie
4 connect microphone cord to aft side of straps (2, table 3-1).
control unit (9) at connector P562 (para 2-17). f. Perform operational check of system
Stow microphone (8) on holder. (para 2-6).
i. Perform operational check of system
(para 2-6).
2-14. INSPECTION.
2-12. CIRCUIT BREAKER.

a. Verify BATTERY-OFF-EXT PWR switch 2-15. Inspect components of public address and
at OFF position, siren system in accordance with the following:
2-4
L2
P560 J1
LS(DS)I FWD
/CORDFURNISHED L1 GRAY A
WITH MICROPHONE
TD4A14
BLK B
L2
I LS(DS)ZIAFT TD3A14
P562 1 J201
L2 (NOTE 3)
J2031P561 P5591J4
C GRD
A BLU A PREAMPOUTPUT
B GRD PTT
B ~--YEL B GRD ISWITCHED) BY PTT
A MIC HI PTT
CM88B I ID ~WHTI i, ID LIGHT
MICROPHONE IAI I I EC RED E LIGHT
B I I 28 VDC
F CGRN I
F
RMC-IS-A C BLK C GRD

CONTROLUNIT TD2A20
1)
W3BUS
JUMPER AWG
ETON(22 52
A
r-P50bA"O--W I~
1 ~2
FUSE
CB129
25A P558 J3
r -P506AK10 ~P506U8 GRAY A 28 VDC
5 TB6
L,
CB122 4 B GRD MA-500
6 ~-BLK
AMPLIFIER
7 I/ (NOTE 2)TolA14
1 EXTPWR GRD
P506AL10 2
L----- OFF
L----- 30
SZSWITCH BAT
WIRETABLE
WIRE NO. CUT LENGTH FROM TERMINATION TO TERMINATION
P506U8 24. 00 W3-6 MS25036-115 CB 129-1 MS25036-115

TD4A14 15. 00 LS(DS)1-L1 h11525036-153 LS(DS)2-L2 MS25036-153
GRAY (NOTE 3) LS(DS)2-L2 MS25036-153 P560-A SOLDER
TO)ALP
BLK INOTE 3) LSIDS)2-LI 1\11525036-153 P560-B SOLDER
JUMPER (NOTE 1) SHLD (TD2A-20) 0121 P559-C SOLDER
BLK (NOTE 1) P561-C SOLDER P559-C SOLDER
YEL (NOTE 1) P561-B SOLDER P559-8 SOLDER
(NOTE 1)~ I TD2A20 I BLU I (NOTE 1) P561-A SOLDER P559-A SOLDER

WHT (NOTE 1) P561-D SOLDER P559-D SOLDER
RED INOTE 1) P561-E SOLDER P559-E SOLDER
GRN (NOTE 1) P561-F SOLDER P559-F SOLDER
GRAY (NOTE 2) P558-A SOLDER CB129-2 MS 25036- 153
TDIA14
BLK (NOTE 2) P558-8 SOLDER TB6-4 MS25036- 108
(NOTE 2) NOTES:
i. CONTROL UNIT INPUT WIRE HARNESS ASSEMBLY.
2. POWER INPUT WIRE HARNESS ASSEMBLY.
3. LOUDS PEAKER OUTPUT W IRE HARNESS ASSEMBLY.

(NOTE 3) ~o 4. W3 BUS AND ITEMS INDICATED BY DASHED
L INES ARE PART OF HEL I CO PTER ELECTR ICAL SYSTEM.
47-302
Figure 2-2. System wiring diagram
2-5
Section 2 Opt Eqpt Manual CSP-033:
Inspect condition of wire harness assemblies

a. a. Replace damaged or frayed wiring and
and wiring connectors at control unit (9, fig. 1-1), connectors.
amplifier (28), and loudspeaker (23). b. Replace damaged loudspeakers and external
b. Inspect loudspeakers and external brackets brackets.
for deformation and damage. c. Replace grommet (24). Check proper instal-
c. Inspect grommet (24) for deformation, lation in doubler as shown in figure 2-1.
damage, and proper installation.
2-16. REPAIR. 2-18. WIRING DIAGRAM.
2-17. Repair of public address and siren system
is limited to replacement of defective or damaged 2-19. See figure 2-2 for the public address and
parts as follows: siren system wiring diagram.
2-6
SECTION 3
3-1. GENERAL INFORMATION. and expendable items as well as electrical com-
ponents required for installation. Items listed

are recommended items of a commercial nature
3-2. SCOPE. Procedures in this section may be
which may be procured locally. Alternate, but
performed at operators discretion and are appli-
cable to all Model 369D helicopters. These equivalent, items are acceptable.
instructions provide for the installation of the
3-4. PREPARATION FOR INSTALLATION.
public address and siren system, and include a
modification to the helicopter structure just Preparation for installation of the public address
and siren system includes the following:
forward and below the right door on the pilots
a. Check all electrical switches for OFF posi-
compartment.
tion, and ensure that BATTERY-OFF-EXT PWR
switch is at OFF.
3-3. REFERENCE DATA. Reference is made in b. Identify all components, including attaching
the instructions to applicable data in HMI Vol 1 hardware, to be removed for access to work areas.
required for the public address and siren system Protect components from damage and foreign
installation. Table 3-1 lists consumable materials matter until reinstalled.
Commercial Product(a)
Item
No. Material Specification No.(l) Name/No. Manufacturer
1 Primer, zinc chromate MIL-P-8585 (3)
2 Tie strap, nylon MS17821-1-9 Ty-Rap
3 Sleeving, tube, 1/4-inch, RNF-100 Transparent Products,

white Los Angeles, CA

black Los Angeles, CA
5 Sleeving, tube, 1/2-inch RNF-100 Transparent Products,


NOTES: (1) Numbers are U.S.A. Specifications and Standards. The prefix symbols are defined as
follows: AMS American Material Standard; MS Military Standard; MIL Military
Specification; Single, double, or triple alpha prefix of the same letter Federal Speci-
fication; AN Air Force-Navy Aeronautical Standard; NAS National Aerospace Standard.
3-1
3-5. REMOVAL OF HELICOPTER EQUIPMENT. 2. When providing ground for electrical com-
ponents or for electrical bonding purposes,

3-6. Prior to installing the public address and clean designated structure areas to bare
siren system, a limited number of items must be metal surface as specified in section 19,
removed from the helicopter to accommodate the HMI Vol 1.
installation. Refer to HMI Vol 1 and perform
the following: 3. Do not tighten electrical clamps or secure
a. Remove left.and right access doors from electrical wiring to existing harnesses
pilots floor compartment. until all electrical wiring is installed.
b. If applicable, remove stowage box from
pilots right side floor compartment. 3-11. AMPLIFIER ASSEMBLY. following The
c. Remove seats from crew compartment. defines procedure
a for
reinforcing the electronics
d. Remove hood and right side fairing from equipment floor structure, and for installing the
instrument panel structure, amplifier assembly.
a. Using drill motor and appropriate drill bit,
3-7. MODIFICATION OF HELICOPTER. remove rivets securing existing two nutplates to
existing support channel(41, fig. 1-1) installed

3-8. helicopter (fig. 3-1)
Modification of the on electronics compartment floor.
consists of providing an access port for the loud- b. Drill and enlarge existing holes in support
speaker output wire harness assembly through channel to 0.257-inch diameter holes. Install
the fuselage skin at the pilots right side floor rivnuts (44) in support channel using rivnut
compartment as follows: header.
a. Locate and mark hole center for cutout in c. Drill and enlarge two existing holes in new
fuselage skin. Center of cutout is located on support channel (41) to 0.204-inch diameter holes
right side of pilots compartment 2.06 ~t0.06 inches for installation of nutplates (43). Using nutplates
below longeron at WL 15.75 and 1.89 ~t0.06 inches (43) as templates, drill four 0.098-inch diameter
aft of station 44.65. rivet attach holes in channel (41) and secure nut-
b. Using chassis punch or equivalent, cut plates (43) to support channel (41) with rivets (42).
0.85-inch diameter hole in fuselage skin as d. Using support channel (41) as template,
required. drill 0.098-inch diameter rivet attach holes in
electronics compartment floor, frame structure
NOTE: For installation of doubler on cutout at station 50. 50, and canted station 64.365 as
in fuselage skin, refer to paragraph 3-12. shown in figure 3-1. Attach support channel (41,
fig. 1-1) to electronics compartment with rivets
3-9. INSTALLATION OF SYSTEM COMPONENTS. (40).
3-10. GENERAL. Installation of the public NOTE: When installing support hardware for
address and siren system includes procedures for amplifier, provide ground by cleaning contact
installing the amplifier on channel supports in surfaces of compartment floor, hardware,
the electronics compartment, loudspeakers on and amplifier to bare metal.
brackets just forward and below the right door of
the pilots compartment, control unit and micro- e. Using screws (36) and washers (37), attach
phone with support on the upper right side of the forward and aft supports (38, 39) to support
instrument panel, circuit breaker on the lower channel (41) and existing channel.
circuit breaker and switch panel, and wire har- I. Using screws (32), washers (33), and nuts
ness assemblies for the system. The general (345, attach channel assembly (35) to forward and
notes that apply to the subsequent procedures aftsupports (38, 39).
are as follows: gUsing screws (29) and washers (30), attach
supports (31) to channel assembly (35).
NOTES:
NOTE: Nutplates are provided to secure
1. After drilling cutting operations,
or screws (29) on channel assembly (35).
remove burrs and metalparticles. Apply
a thin coat of zinc chromate primer (1, h. Using washer (27) and existing amplifier
table 3-1) installing rivets or to bare
when bolts,attach amplifier (28) to supports (31) on
metalareas, except when hole is to be used channel assembly (35).
for electrical ground or bonding purposes.
Color matched paint may be applied over NOTE: Electrical wiring at amplifier (28) is not
zinc chromate primed areas. installed at this time (refer to paragraph 3-15).
3-2
FWD
I i
r--------~
LOWER DOOR
\I
HINGE AREA N
Jl
r-----!/
__ _ _
_
_ _ ___
r
MOUNTING I
BRACKET\1 I
RH LONGERON
XI
WL 15. 75
t
It
2. 06~ 0. 06
INCHES
/r
fS_
GROMMET
DOUBLER (NOTE 1)
0.85-INCH DIAMETER
1. 89~ 0. 06
CUTOUT IN FUSELAGE
INCHES STA
SKIN
44.65
O FUSELAGE CUTOUT AND
FWD
MA-500 AMPLIFIER
STUNVIRRELBUOD
CANTED
STA 64.365
EXISTING
SUPPORT
STA
CHANNEL
50.50
i
BL
A
:E I 8. 782 INCHES
NUTPLATES
EXISTING SUPPORT
A
CHANNEL NEW SUP
NEW SUPPORT CHANNEL
ELE CTRON I CS
COMPARTMENT/ CHANNEL
INBD -~3.4851NCHES
AMPLIFIER SUPPORT CHANNELS VIEV A-A
O (LOOKING INBOARD FROM LEFT SIDE) SUPPORT CHANNEL
LOCATION
47-304-1
Figure 3-1. Modification and relnforcement; dimen,sions (sheet 1 of 2)
3-3
INSTRUMENT PANEL
CM 888
B7 J MICROPHONE
NOTES:
i. DOUBLER ON FUSELAGE SKIN REQUIRES

SIX EQUALLY SPACED RIVETS.
2. EXISTING RIVET HOLES ARE ENLARGED

00 FORNUTPLATE INSTALLATIONS. DETERMINE
O NUTPLATE LOCATI ON S FROM EX I STI NG
RIVETS ABOVE AND BELOW EXI STING
U NUTPLATES, STRUCTURE LIGHTENING
HOLES, AND STRUCTURE STIFFENER AS SHOWN.
RMC-IS-A
CONTROL UNIT
SUPPORT
INSTRUMENT PANEL
LORTNOCDNA
UNIT
EX ISTING NUTPLATE
STRUCTURE LIGHTENING
HOLE (TYP I GAL)
HOOD\ I- -i 2. 06~ 0. 06 INCHES

i I
I
:S
FWD
i I
I+ I+,iiI j
I 1,1
i~ WL 305~ 0. 06 INCHES
i+ 40.40
;I I +I i. 25-INCH DIAMETER
CUTOUT IN FAIRING
NUTPLATES FOR I I,,

CONTROL UNIT
Y---~- GROMMET
SUPPORT (NOTE 2) I
Il I$ I;
II I+ LI-l
STRUCTURE STIFFENER I
I,~
SI DE FAIRING
EXISTING
NUTPLATE
ii ;_
STA
STRUCTURE
40. 00
VIEW B-B
NUTPLATE AND CUTOUT LOCATIONS
47-304-2
%igure 3-1. Modification and reinforcement dimensions (sheet 2 of 2)
3-4
3-12. LOUDSPEAKER ASSEMBLY. The following 4. Verify loudspeakers are properly installed
defines a procedure for installing the loudspeaker on (20)
bracket and that horn nut is secured
and support brackets on the helicopter, including (para 2-10).
a doubler on the cutout in the fuselage skin just
forward and below the-right side pilots compart- NOTE: Electrical wiring at loudspeakers is
ment door. notinstalled at this time (refer to paragraph
a. Use doubler (26, fig. l-lj template, and
as 3-15).
determine six rivet hole locations required through
fuselage skin. Using drill motor and appropriate 3-13. CONTROL~UNIT AND MICROPHONE. The
bit,drill 0.098-inch diameter rivet attach holes following defines a procedure for installing the
around circumference of cutout. Attach doubler control unit and microphone on the right side of
(26) to fuselage skin with rivets (25) as shown in the instrument panel.
figure 3-1. a. Determine four hole locations onright side
b. Installgrommet (24, fig. 1;-1) in fuselage of instrument panel structure for nutplates (15)
skin cutout, as required. asshownin figure 3-1, Using drill motor and
c. Verify that loudspeakers (23) are installe$ appropriate drillbit, remove applicable existing
onbracket (20), and that bracket (21) is discon- rivets in structure and enlarge to.0.l77-inch
nected from bracket (20). diameter holes. drill,b.098-inch diameter
Also,
rivet attach holes at each nutplate (15, -fig; 1-1)
NOTES: hole. Attach nutplates (15) to, structure with
rivets (14).
1. To-facilitate installation ofbrackets (20, 21) b. Position hood and side fairing, oninstrument
make certain that bracket (21) is discon- panel structure, and determine access holes to
nected from bracket (20). nutplates (15) on structure; then remove hood and
fairing. Drill two 0.177-inch diameter holes in
2. Nipples (22) used for protection of terminals fairing to match nutplates (15) as shown in
at loudspeaker units may be stowed on wire figure 3-1.
harness or provided as loose equipment. c. Using upper forward access holein side
fairing as.reference, determine location of cutout
d. Position bracket (21) on outer fuselage skin, for electrical wiring as shown in figure 3-1.
at right longeron (WL 15.75) and bulkhead (station Using 1.25-inch-diameter chassis punch or equi-
64.65), and determine rivet hole locations for valent, cut, hole in fairing as shown;; then install
bracket as shown. Drill 1.285-inch diameter grommet (13,-fig. l-lj in hole.
rivet attach holes in bracket (21), and remove d. Position control unit-support (12) over nut-
existing three rivets at right longeron and existing plate access holes on side fairing. Mark and
three rivets at bulkhead. Attach bracket (21j to drill four 0.177-inch diameter screw attach holes
fuselage skin with rivets (19). in support (12) for eventual attachment to nutplates
Position bracket (20) on bracket (21) and
e, (15).
determine rivet hole locations for upper and lower e. Install side fairing and hood on instrument
tabs on bracket (20) as shown. Drill two 0.204- panel structure (HMI Vol 1).
inch diameter screw attach holes in bracket (20) f. Using screws (10) and washers (11), attach
to match nutplate attachment on bracket (21). support (12) to nutplatesi(l5) on instrument panel.
f. Remove two existing rivets from station g. Verify that microphone holder is attached to
50. 50, just below right longeron, corresponding support (12) with screws (5), washers (6), and nuts
to lower left tab on bracket (20); then drill two (7); then attach control unit (9) in support (12) with
1.28 5-inch diameter rivet attach holes in lower screws ~upplied with unit. Stow microphone (8) in
left tab to match rivet pattern. holder on control unit (9).
g. Using screws (16) and washers (17), attach
NOTE: Electrical wiring at control unit (9) is
bracket (20) to nutplates on bracket (21). not installed at this time (refer to paragraph
Using rivets (19), attach lower left tab of
h.
3-15).
bracket (20) to station 50.50, just below right
longeron as shown. 3-14. CIRCUIT BREAKER. Forinstallationof
Mark and drill two 0.169-inch diameter circuit breaker 74), refer to paragraph 2-~i2.
screw attach holes through upper tab of bracket
(20) and fuselage skin at station 43.00, just above 3-15. ELECTRICAL WIRING. The following
WL 22.00. defines a procedureforinstI~ling the wire harness
Using screws (16), washers (17), and nuts assemblies (1, 2, 3) in accordance with the wiring
(18), attach upper tab of bracket (20) to fuselage diagram and wiring table in figure 2-2 and the
skin as shown. steps that follow.
5-5
a. Connect loudspeaker output wire harness c. Connect control unit input wire harness
assembly (3, fig. 1-1) to amplifier (28) and assembly (1, fig. 1-1) to amplifier (28) and
loudspeaker assembly (23) as follows: control unit (9) as follows:
(1) Connect wire harness receptacle to (1) Connect wire harness receptacle to
amplifier (28) at connector P560. amplifier (28) at connector P559.
(2) Route wiring under pilots compartment (2) Route wiring from electronics com-
floor, and through grommet (24) in lower-forward partment under pilots compartment floor to aft
right side of fuselage. Use nylon tie straps (2, side of instrument panel, and through grommet
table 3-1) to secure wiring as required.
(13) in upper right side fairing.
(3) Connect gray wire, with white sleeving (3) Connect wire harness receptacle to
(3), to forward loudspeaker connector LS(DS)1-L1. control unit (9) at connector P561.
(4) Connect black wire, with black sleeving
(4), to aft loudspeaker connector LS(DS)B-L1. NOTE: Wire harness between amplifier and
(5) Connect wire No. TD4A~4, with pro- control unit is covered with black sleeving
tectivesleeving, to loudspeaker connectors (5, table 3-1).
LS(DS)1-L1 and LS(DS)2-L.
(6) Install nipples (22, fig. 1-1) to protect (4) Connect microphone receptacle to con-
terminals at connectors. trol unit (9)
at connector P562.
(7) Secure loudspeaker terminal wiring d. Perform operational check of system
with cable tie attached to bracket assembly (20), (para 2-6).
NOTE: Wire harness between

amplifier and 3-16. INSTALLATION OF HELICOPTER
cable tie betweenloudspeakers is covered EQUIPMENT.
with black sleeving (6, table 3-1).
3-17. After installation of public address and
b_. Connect power input wire harness assembly siren system, a limited number of items must be
(2, fig. lil) to amplifier (28), circuit breaker replaced in the helicopter. Refer to HMI Vol 1
(4), and helicopter ground as follows: and perform the following:
(1) Connect wire harness receptacle to a. Install seats in crew compartment.
amplifier (28) at connector P558. b. If applicable, install stowage box in pilots
(2) Route wiring from electronics compart- right side floor compartment.
ment under pilots compartment floor to aft side c. Install left and right access doors on pilots
of lower circuit breaker and switch panel. Use floor compartment.
nylon tie straps (2, table 3-1) to secure wiring
as required.
3-18. WEIGHT AND BALANCE DATA.
(3) Connect gray wire, with white sleeving
(3, table 2-1), to circuit breaker terminal 3-19. Weight and balance data resulting from
CB129-2.
installation of the public address and siren sys-
(4) Verify that wire No. P506U8 with tem is listed in table 3-2. After installation,
terminals M525036-115 at each end, and protec-
incorporate changes in helicopter weight and
tive sleeving, is connected to circuit breaker balance records instructed in HMI
as Vol 2.
(CB129) terminal (2) and bus (W3) terminal (6)
(section 20, HMI Vol i). Table 3-2. Weight and balance data
(5) Connect black wire, withblack sleeving
(4), to helicopter ground at TB6-4 (section 20, Weight Arm Moment
HMI- Vol 1). Item (Ib) tin.) tin. -lb/100)
-501 Kit (complete)

N(TrE: Wire harness between amplifier and Added 32.4 47.7 1 54 5
cable tie aft of lower circuit breaker and Removed 0 0 0
switch panel is covered with black sleeving C hanged 32.4 47.7 1 54 5
(6, table 3-1).
3-6
CSP
036

arnd
FOR
SEATING AND BELTS FOR FOUR INSTALLATION
Part No. 369)1190035-501
USED ON NUGHES 500D (MODEL 369D) HELICOPTERS
AND
Part No. 3691190035-503
USED ON HUGHES 500E AND 530F (MODELS 3693 AND 369F) HELICOPTERS
~Hughe. Helicopter.. Inc.

c.l,,c., C.lila~ni14.2P

Reissued 15 January 1985
NI FG I
INTRO
C3P-036 Opt Eqpt Manual
INSEPT LATEST CHANGED PAGES, DESTROI SUPCIISLOEO PAGES.

LIST OF EFFECTIVE PAGES THE ASTERISK INDICATES PAGES CHANGED. ADDED. OA DELETED BY THE CVRRENT CHANGE.
Title Original F-2 Blank Original

A thru B............. Original 1-1 thru 1-5 Original
C Blank Original 1-6 Blank Original
i Original 2-1............... Original
ii Blank Original 2-2 Blank Original
F-l Original 3-1 thru 3-7 Original
3-8 Blank........... Original
A Reissued 15 January 1985

use
revisions.
Hughes Helicopters

6/A141
Originator
Address
Figure Number(s)
nemarks/necommendations
Reissued 15 U C
January 1985
OF REVISIONS
CSP-036
MFG REV
CSP-036 Reissue 1/15/85 9/13/85 ATP/KK


CSP-036
Opt Eqpt Manual Table of Contents
TABLE OF CONTENTS
Section Page
FOREWORD F-l

of this Manual F-l
F1
F-3. Applicability...
Combined Optional
Fr
Equipment....
of Contents. F-l
F-7. Organizatioh
F-9. Use of this Manual F-I
F-ll. Related Publications F-l
Revfsions.... F1
ILLUSTRATED PARTS LIST r-1

I
1-1
1-1. Scope and Contents.....
1-3. Group Assembly
Parts List 1-1
1-5. Illustrations 11
Usable on Code 1-1

1-7.
Section Page
2 MAWTENANCE INSTRUC-
TIONS......... 2-1
2-1. General Information... 2-1

2-5. AdfusCments....... 2-1
2-7. Removal........... 2-1
2-9. Inspection......... 2-1
2-11. Cleaning 2-1
2-13. Repair/Replacement 2-1
2-15. Installation 2-1
3 INSTALLATiON WSTRUC-
Reissued 15 January 1985 i/ii
TIONS 3-1
3-1. General Information... 3-1

Equipment.......... 3-1
3-7. Installation of Seating
and Belts for Four Kit. 3-2
3-13. Weight and Balance Data 3-6
FOREWORD
tained in the Basic Handbook of Maintenance these are presented in sequence as defined in
Instructions (HMI Vol 1) and the Illustrated section 1, HMI Vol 1.
Parts Catalog (IPC), and contains instructions
for initial installation and continuing maintenance
F-9. USE OF THIS MANUAL.
for the seating and belts for four installation.
This passenger compartment installation is
sometimes referred to as the "Four on the F-10. This manual is for use by operators of the
Floor" configuration. Weight and balance model 369D/E/F helicopter equipped with a seat-
data is included. This manual also contains ing and belts for four installation. Although this
parts lists for procuring replacement parts for manual is a separate publication, it should be
the seating and belts for four installation. kept with HMI Vol 1, HMI Vo12, the IPC
and other handbooks listed in section 1, HMI
F-3. APPLICABILITY. Vol 1 that form the primary information file for
the helicopter.
F-4. The seating and belts for four installation
is applicable for use on any Hughes 500D (Model F-ll. RELATED PUBLICATIONS.
369D), 500E (Model 3893) and 530F (Model
369F) helicopter.
of HMI Vol 1, the IPC and applicable Opt
OPTIONAL EQUIPMENT.
Eqpt Manuals as required to accomplish instruc-
F-6. Forcompatibility information on which tions contained herein.
combination at the same time, refer to section
F-13. LITERATURE CHANGES AND
21, HI1II- Vol 1. REVISIONS.

F-8. The contents of this manual are grouped manual are made as defined in section 1, NMI
Reissued 15 January 1985 F-1/F-2

SECTION 1

1-2. This illustrated parts list provides, by each group assembly parts list. Each illustra-
tion is exploded to the extent necessary to show
trations, a complete parts definition of the seat-
parts relationship for the seating and belts for
ing and belts for four installation configu~ation,
four installation.
manufactured by Hughes Helicopters, Inc.,
Culver City, California.
NOTE: The illustrated parts list is organized 1-8. The USABLE ON CODE column located at
and presented in the same manner as the the right-handside of the Group Assembly Parts
369Dand 369E/F Series Illustrated Parts List pages indicates the effectivity of parts by
Catalog. (For information on use, refer to aircraft serialnumber. In many cases two
369D IPC or 369E/F IPC. different parts are listed, one representing the
1-4. The parts list furnish information for pro- ON CODE is listed, items are understood to have
curing replacement parts for the seating and full effectivity.
belts for four installation and shall not be used
A 3693 S/N 0001 and subsequent and
for any other purpose. For information or pro-
I curement of other replacement parts, refer to

the appropriate IPC. B
369B S/N 0003 and subsequent
369D S/N 0003 and subsequent
Reissued 15 January 1985 1-1

5
3
1819 10 10
SEAT BELTS AND SHOULDER

STRAPS, AFT SEATS
R 1~
d
STRAPS, FORWARD SEATS
RESTRAINT PANELS ON
O CANTED STATION 78.50
47-326-1
Figure 1-1. Seating and Belts for Four Assembly 369E/F Helicopters
1-2 Reissued 15 January 1985

UNITS USABLE
FIG.
INDEX I PART DESCRIPTION I PER ON
ASSY CODE
NO. NO.
1-1- 3691190035-503 1 SEATING AND BELTS FOR FOUR I I A

INSTALLATION
-1 1 369H92252-27 1 SEAT BELTASSEMBLY, RH FWD 1
1 SEAT BELTASSEMBLY, RHFWD 1

369B92252-3
(For replacementorder 369B92252-27)
-2 1 369B92252-29 1 SEAT BELT ASSEMBLY, LH FWD 1~. I 1
369B92252-5 SEAT BELTASSEMBLY, LH FWD 1

(For replacement order 369B92252-29)
-3 1 369B6662 1. FITTINGASSEMBLY 1 4
-4 369B92252131 1 SEAT BELTASSEMBLY, LHAFT.,....... 1
369B92252-7 1 SEAT BELT ASSEMBLY, LHAFT,........ 1

-5 1 369B92252-33 1 SEAT BELTASSEMBLY, RHAF~......... 1
369B92252-9 SEAT RH AFT......... 1

-6 369B6513-3, 1 SHOULDERSTRAPS 2
-7 NAS62 3 -3-4 1 SCREW 8
-8 1 ANg60PD1OL WASHER 1 8
-9 369B92250 FITTING SUPPORT. 2
-10 369H92253-503 SEATASSEMBLY 4

369Hg2253-5 1 SEATASSEMBLY (Two way intrchwith 4
369B92253-503 in ship sets)
-11 NAS514P1032-8 SCREW 8
-12 5724-17 WASHER 8

369B90035-19 1 RESTRAINT PANEL, RH 1
-13
-14 369B90035-14 RESTRAINT PANEL, LH 1
-15 NAS 1398 B4 -2 1 RIVET .........-.......i 1 8
-16 369B90035-5 1 2
-17 369B90035-41 1. BRACKETASSEMBLY I 2:IA

-19 369B90035-9 BRACKETASSEMBLY 1 4

8
9
!8 5
0 I A 24
/I/ a
24 4
25 10
O SEAT BELTS AND SHOULDER

STRAPS AFT SEATS
20
FORWARDSEATS,
STRAPS,
~B j/O IIBTRI\NTPIINILEON
STATION 78. 50 CANTED
,17
12
18
d"
O FITTING CAP AND FITTING
(LH SHOWN)
47-326-2
Figure 1-2, Seating and Belts for Four Assembly 369D Helicopters

Section 1
UNITS USARLE
FIG.
DESCRIPTION PER ON
INDEX PART
ASSY CODE
NO. NO.
B
1-2- 369B90035-501 SEATINGAND BELTS FORFOUR
INSTALLATION
1
-1 3691192252-27 SEAT BELT ASSEMBLY, RH FWD
1
369B92252-3 SEAT BELTASSEMBLY, RH FWD
LH FWD 1
-2 1 369B92252-29 SEAT BELTASSEMBLY,
LH FWD 1
369B92252-5 SEAT BELTASSEMBLY,
4
-3 369H6662 FITTING ASSEMBLY
1
-4 369B92252-31 SEAT BELT ASSEMBLY, LH AFT
1
369B92252-7 SEAT BELT ASSEMBLY, LH AFT
(For replacement order 3691192252-31)
RH AFT 3
-5 1 369B92252-33 SEAT BELT ASSEMBLY,
RH AFT 1
369B92252-9 SEAT BELT ASSEMBLY,
SHOULDERSTRAPS 4
-6 369B6513-3
8
-7 NAS623-3-4 SCREW
8
-8 AN960PD10L WASHER...........
2
-9 3691192250 FITTING SUPPORT
4
-10 369B92253-503 SEAT ASSEMBLY
4
369B92253-501 SEAT ASSEMBLY (Two way intrch with
369B92253-503 in ship sets)
-11 NAS514P1032-8 SCREW
8
-12 5724-17 WASHER...........
1
-13 369B90035-19 RESTRAINT PANEL, RH
LH 1
-14 369B90035-14 RESTRAINT PANEL,
4
-15 MS352 06 -245 SCREW
1
-16 369B90035-4 CAP, FITTING, RH
1
-17 369B90035-3 CAP, FITTING, LH
8
-18 MS24603C272 SCREW
1
-19 369B92508-2 FITTING, RH
1
-20 369B92508-1 FITTING, LH
8
-21 NAS 1398B4-2 RNET
2
-22 369B90035-5 BRACKET ASSEMBLY
BRACKET ASSEMBLY 2
-23 369H90035-7
RIVE T AR
-24 MS2 04 70AD4
BRACKETASSEMBLY 4
-25 369B90035-9 1
1-51-6
SECTION 2
2-1. GENERALINFORMATION. 2-9. MSPECTION.
2-2. SCOPE. This section provides description 2-10. Inspect components of the seating and
and maintenance instructions for the seating and belts for four as follows:
belts for four kit, a. Inspect seat and restraint panel covering
for tears, cuts, breaks or other evidence of
2-3. REFERENCE DATA. Wheredirectedin unserviceable condition.
the following procedures, refer to the Handbook b. Inspect full length of seat belts and shoulder
of Maintenance Instructions, Volume 1 (HMI straps for loose stitching, fraying and fabric wear
Vol 1) for supplementary information and and deterioration.
procedures, c. Inspect seat belt and shoulder strap end

fittings, buckles, and latches for cracks, corro-
2-4. DESCRIPTION. The seatingandbeltsfor sion, deformation and excessive wear.
four kit is designed for maximum use of

the passenger compartment for transportation of 2-11. CLEANING.
personnel. The kit consist of four floor installed
seat assemblies, with seat belts and shoulder 2-12. Refer to HMI Vol 1 for interior cleaning
straps at each position. The two aft facing seat procedures.
positions include head back restraint panels
mounted on canted station 78. 50 structure. 2-13. REPAIR/REPLACEMENT.
Shoulder straps for aft facing passengers are
installed on Model 3691) helicopters only. 2-14. Refer to HMI Vol 1 for repair of minor
tears and cuts to the seat and restraint panel
2-5. ADJUSTMENTS.
coverings.
2-6. The shoulder strap is adjusted to cross a. Replace unserviceable seats and restraint
passengers chest from outboard shoulder to panels.
center of lap where it joins the seat belt assem- b. Seat belts or shoulder straps that show
bly. Seat belts are individual pas-
adjusted by signs of wear, deterioration, fraying and loose
sengers for a close and comfortable fit. stitching must be replaced.
2-7. REMOVAL. 2-15. INSTALLATION.
I
2-8. Remove
belts for four kits
components
as
of the
follows:
seating and 2-16. Install components of the
for four kits as follows:
seating and belts
I
a. Remove seat assemblies by lifting tabbed a. Install seat assemblies by placing seat in
rivets from holes in floor stiffeners, (two per position and inserting tabbed rivets into holes in
seat), then lift seat up. floor stiffeners.
b. Remove restraint panels by removing four b. Install restraint panels by securing each
bolts and washers from each panel. panel with four bolts with accompanying washers.
c. Remove seat belts assemblies and shoulder c. Install seat belt assemblies and shoulder
straps by unsnapping hooks at structure mounted straps by snapping hooks to structure mounted
fittings. fittings.
Reissued 15 January 1985 2-1/2-2

SECTION 3
3-1. GENERAL INFORMATION. Protect components from damage and foreig?l

matter until reinstalled.
3-2. SCOPE. Proceduresinthis sectionmay
c. After drilling or cutting, remove burrs and
be performed at the operators discretion and
metal particles. Apply a thin coat of zinc ctlro-
are applicable to all 3S9D/369E/369F series
mate to bare metal areas.
helicopters. These instructions provide for the
installation of the seating and belts for four kit NOTE: An application of color-matched p;lint
and include modifications to canted station 78. 50 applied to primer painted reworked
structure, areas and to installed hardware.
3-5. REMOVAL OF HELICOPTER EQUIPMENT.

3-3. REFERENCE DATA. Referenceismade
in the instructions to applicable data in HMI 3-6. Prior to installing the seating and belts for
Vol 1 required for the seating and belts for four four limited number of items must be re-
kit, a
installation. Table 3-1lists consumable mate- moved from the helicopter aft compartment to
rials and expendable items required for installa- accommodate kit installation. Refer to HMI
tion of the complete seating and belts for four Vol 1 and remove the following:
kit. Items listed are recommended items of a a. Aft compartment seats by releasing quick
commercial nature which may be procured disconnects on seating structure at floor and
locally. Alternate, but equivalent, items are firewall fittings.

acceptable. b. Existing aft seat belt and shoulder strap
assemblies.
3-4. PREPARATION FOR MSTALLATION. c. Aft
carpet floor covering.
d. Aft trim panel from canted station 78. 50,
belts for four kit includes the following: disconnect cigarette lighter wiring.
all electrical switches for off posi-
kcehCot
tion, and ensure that master switch is set
e. Bulkhead trim panels or insulation blankets
at station 124. 00 in area of WL 40. 00 and
OFF. BL 20.00 right and left sides.
b. Identify allcomponents, including attaching f. Forward compartment outboard seat backs
hardware, to be removed for access to work areas. (3F9D only).
Table 3-1. Consumable Materials and Expendable Items
Commercial Product(2)
Item
No. Material
(1)
Specification No. Name/No. Manufacturer
1 Primer, zinc TT-P-1757 (3)

chrom ate

Specifications and Standards. The prefix symbols are defined as
Specification; Single, double or triple alpha prefix of the same letter Federal S~ecifi-

3-7. INSTALLATION OF SEATING AND BELTS (2) Install bracket assembly with two blind
FOR FOUR KIT. rivets (15).
(3) On WL 37. 85, position bracket assem-
3-8. Installation of the seating and belts for four bly (16) BL 8. 50 LH. Drill two 0. 1285-inch
kit includes procedures for installing restraint diameter holes through bracket and canted
panels on canted station 78. 50, seat assemblies, station 78. 50 channel. (See figure 3-1.)
shoulder straps and seat belt assemblies. (4) Install bracket assembly with two blind
rivets (15).
NOTE: Use Cleco clamps and fasteners as
(5) Repeat steps (1) through (4) to install
required to facilitate rivet installation and
bracket assemblies (16 and 17) RH opposite.
install rivets with wet zinc chromate primer
(1, table 3-1).
NOTE: Continue with step h for installation
Rivets are equally spaced and are normally
offittings (19 20) on 369D helicopters.
and
positioned twice the diameter of the rivet
For 369E/F helicopters, continue with
shank from the outside edge of the material,
step o.
edge joggle or flange radius.
3-9. CANTED STATION 78.50, BRACKETS, h. On left side of canted station 78. 50 bulk-
FITTDNGS AND RESTRAINT PANELS. head frame, locate four existing nutplates in
a. On canted station 78. 50, WL 22. 45, remove area of WL 41.06 and BL 24. 74.
four existing rivets in area of LBL 8. 25 and four i. Attach shoulder strap fitting (20) with four
rivets in area of LBL 19. 25 as shown in fig- screws (18).
ure (369E/F helicopters)
3-1 or 3-2 (369D j. On right side of canted station 78. 50 bulk-
helicopters). head frame, locate four existing nutplates in
Position two bracket assemblies (19, fig,
b. area of WL 41. 06 and BL 24. 74.
l-T or 25, fig. 1-2), locate and drill four 0. 1285- k. Attach shoulder strap fitting (19) with four
inch diameter holes in each bracket, matching screws (18).
holes in removed rivet pattern. See figure 3-1 I. Attach LH fitting (20) to nutplates in LH
for 369E/F helicopters or figure 3-2 for 369D teeusing four screws (18).
helicopters. m. Attach RH fitting (19) to nutplates in RH
c. Hold brackets in position with Cleco faste- teeusing four screws (18).
ners and drill four O. 1285-inch diameter holes n. Cut out slots in removed, passenger com-
through upper flange of each bracket and through partment forward trim panels to accommodate
canted station 78. 50 web. lugs of shoulder strap fittings.
d. Install bracket assemblies with 16 rivets o. Drill four 0. 217/0. 229-inch diameter holes
(18~ fig. 1-1 or 24, fig. 1-2). inTorward trim panel and four holes in each
e. Repeat steps a through d to install two restraint panel (13 and 14). Locate holes from
bracket assemblies719, fig. T-l or 25, fig. 1-2) bracket assemblies (16, 17, 19, fig. 1-1 or 22,
to opposite side. 23, 25, fig. 1-2) and install as in steps a
Install bracket assemblies (22 and 23) on
f. through j.
369D helicopters as follows. (Refer to step g p. Reinstall forward trim panel, connect ciga-
for 3693 or 369F installation. reffe lighter wiring.
(1) On WL 45. 33, position bracket assem- q. Install fitting cap (17) to LH shoulder strap
bly (23) at LBL 15. 50 and drill two 0. 1285-inch fitiing with two screws (15) (369D helicopters
diameter holes through bracket and canted only).
station 78. 50 channel as shown in figure 3-1. r. Install fitting cap (16) to RH shoulder strap
(2) Install bracket assembly with two blind fitfing with two screws (15) (369D helicopters
rivets (21, fig. 1-1). only).
(3) On WL 45.33 LH, position bracket s. Install restraint panel (14) to LH side over
assembly (22) LBL 8. 50 and drill two 0. 1285- panel with four each, washers (12) and
inch diameter holes through bracket and canted screws (11).
station 78. 50 channel. t. Install restraint panel (13) to RH side over
(4) Install bracket assembly with two blind panel with four each, washers (12) and
rivets (21). screws (11).
(5) Repeat steps (1) through (4) to install u. Reinstall forward compartment seat back
two bracket assemblies (22 and 23) RH opposite. assemblies.
Install bracket assemblies (22 and 23) on
and 369F helicopters as follows. 3-10. SEAT ASSEMBLIES.
(1) On WL 37. 85, position bracket assem- a. (10) on floor
bly (17) at BL 19. 50 LH. Drill two 0. 1285-inch structure to locations specified in figure 3-3.
diameter holes through bracket and canted b. Secure seats in position by pressing tabbed
station 78. 50 channel. (See figure 3-1. rivets into holes in floor stiffeners.

IBL 19.50 LBL 8. 50

BRACKET ASSEMBIY\ I
I /BRACKET
t I ASSEMBLY
IILRm~--wmjq
0.50 (TYPICALI r\--~T,,-l1
RI VET2) RIVET (2)
STA 78. 50
0.83 0.75
r
r
II, f
0. 50 0. 42
i,
O LH SHOWN
RH OPPOSITE
RIVET (81
RIVET 18)
/CANTED BRACKET ASSEMBLY

BRACKET ASSEMBLY STA 78. 50
if
J II
NOTES: I.:..,: ooo. ~a 003 O
i. INSTALL 0.21710.229 HOLES (4)

IN EACH RESTRAINT PANEL
ASSEMBLY; LOCATE FROM
ii--
ils.~
i
c_o_,
i i
_1~Ltli!
"II
i;.
PICK UP EXISTING RIVETS o
BRRCK(TZ. INSTALL HOL~S IN

TRIM PANEL ASSEMBLIES AS
LBL iBL LBL LBL 1BL
APPLICABLE. 6.00
20.75 19.25 17. 00 11.30 8.25
2. ALL DIMENSIONS IN INCHES. IH SHOWN
RH OPPOSITE
LBL LBL BL RBL RBL

19.50 8.50 0.00 8.50 19.50
RESTRAINT PANEL RH RESTRAINT PANEL
I
LH RH
ASSEMBLY
"r D~ ASSEMBLY
RESTRAINT
BRACKET ASSEMBLY
BRACKET
ril PANEL ASSEMBLY
ASSEMBLY
WL 37.85
BRACKET
v
II BRAG KET ASSEMBLY
TRIM
PANEL
/--WL 28.44
BRACKET j k
ASSEMBLY i--WL22.45
i WL 21.50
SEAT
I I BR AC KET A S SEM BLY ASSEMBLY
~RAGKET
LBL 20. 75 LH
ASSEMBLY
,(RB~L 20. 75 RH
LBL 19. 25 LH RBL 19. 25 RH
LBL 17.00 LH RBL 17. 00 RH
LBL 11.30 LH RBL 11.30 RH
LBL8.25LH RBL8.25RH CANTED
STA 78. 50 WL 13. 10~
0 BRACKET LOCATION
SECTION DD 47-327-1
Fig.ure 3-i. Restraint Panel Assemblies and Hardware Installation 369E/F Helicopters
3-3
BRACKET ASSEMBLY LBL 15.50 LBL 8. 50

I ,BRACKET
I ASSEMBLY
RIVET (2) RIVET (2)

CANTED
STA 78.50
0.83 0.75
f t9t
0.50 0.42
O LH SHOWN
RH OPPOSITE
RIVET (8)
RIVET (8)
/CANTED BRACKET ASSEMBLY

BRACKET ASSEMBLY ;_e r STA
78.50,
/li? i
/I i
NOTES: ~II_. O O O O 000
OI! OiC~
1. INSTALL 0.21710.229 HOLES (4) (_O i! O
IN EACH RESTRAINT PANEL ii s liolo~o i, O C7 i~ i) O II C;
ASSEMBLY: LOCATE FROM I

BRACKETS. INSTALL HOLES IN
TRIM PANEL ASSEMBLIES AS
LBL
PICK UP EXISTING
P
LBL LBL LBL LBL LBL
APPLICABLE.
20.75 19.25 17.00 11. 30 8. 25 6.00
2. ALL DIMENSIONS IN INCHES.
Q LH SHOWN
RH OPPOSITE
LBL LBL BL RBL RBL

15. 50 8. 50 0.00 8. 50 15. 50
RESTRAINT PANEL RESTRAINT PANEL
:ipiE~ I
RH RH
ASSEMBLY ASSEMBLY
\\~BRACKETASSEMBLY RESTRAINT
I,BRACKET
11 PANEL ASSEMBLY
BRACKET
ASSEMBLY i
WL 45.30
ASSEMBLY
i !I II BRAG KET ASSEMBLY
FI~TINC
SUPPORT TTING SUPPORT
i
TRIM
SHOULDER STRAP
PANEL
SHOULDER I
BRACKET
ASSEMBLY 0 (Si~ !-WL 22.45
i._- __J--- WL 21. 50 SEAT
P-----,~-- KETASSEMBLY ASSEMBLY
BRACKET
LBL 19. 25 LH ASSEMBLY

RBL 19.25 RH
LBL 17.Mi LH RBL 17. 00 RH
LBL 11. 30 LH RBL 11. 30 RH
LBL 8. 25 LH RBL 8. 25 Rk CANTED
STA 78.50 WL 13.
O RESTRAINT PANELS AND
BRACKETS LOCATIONS 3691) 1DD
SECTION
47-327-2
Figure 9-2, Restraint Panel Assemblies and Hardware Installation 369D Helicopters
3-4
Section 3
SHOULDER STRAP
ATTACHMENTFITTING
L.H. SHOWN
R.H.OPPOSITE\ IQ
B"
SCREW (4 REQO
3690 HELICOPTER
WASHER 14 REPD)
O STA. 124.00 SHOULDER STRAP FITTING
SHOULDER STRAP
ATTACH FITTING
~G
;I R.H. SHOWN
L.H. OPPOSITE
r~ FITTING CAP
R.H. SHOWN
L.H. OPPOSITE
SCREW (4 REQD)
,j
SCREW (2 REPD)
369EIF HELICOPTER
STA. 78. 50 SHOULDER STRAP FITTINGS
NOTES:
i. PICKUP EXISTING NUTPLATES LOCATED ON

CANTED STA 78.50 BULKHEAD FRAME AND
CANTED STA 124,00 BULKHEAD FRAME.
I
SHOULDER Ij SHOU1DER
STRAP
j STRAP (TYP)
r
I
.I i::::i-: :::::l::V: :li~__:

STA 78. 50 WL 28. 44 WL 32. 00 STA 124. 00
O STA 78.50 SHOULDER STRAPS AND FITTINGS O STA.124. W SHOULDER STRAPS AND FITTINGS
47-3288
Figure 3-3. Shoulder Straps and Fittings Installation 369D/E/F Helicopters

CSP-036
Section 3 Opt Eqpt Manual
NOTE: Seat assemblies are position h. Connectadjustable portion of seat belt

assembly (4, fig. 1-1 or 4, fig. 1-2) to LH fitting
inter c hangeable.
and nonadjustable portion of seat belt assembly
3-11. AFT SEAT BELT ASSEMBLIESAND to center fitting.
SHOULDER STRAPS.
a. On both left and right sides of canted sta- 3-12. FORWARD SEAT BELT ASSEMBLIES
tion 128. 00 locate four existing nutplates in areas AND SHOULDER STRAPS.
of WL 40. 00 and BL 20. 00 (reference figure 3-1 a. Connect a shoulder strap to each shoulder
strap support fitting (19 and 20) on canted station
or 3-2).
b. Attach a shoulder strap support fitting 78. 50 (369D helicopters only).
(g,fig. 1-1) on each side using four washers (8)
and four screws (7) for each fitting. NOTE: Adjust shoulder strap to cross pas-
sengers chest from outboard shoulder
to
Cut out slots in removed trim
c. panels or
insulation blankets to accommodate lugs of new inner center lap area.
support fittings.
d. Reinstall trim panels or insulation blankets. b. Locate the four tiedown fitting holes on the
e. Connect a shoulder strap (6), to each first floor stiffener aft of canted station 78. 50
support fitting. (fig. 3-4).

fitting (3, fig. 1-1
to cross pas-
c. Install
or-~, fig.
a cargo tiedown
I
NOTE: Adjust shoulder strap d. Connect adjustable portion of seat belt
sengers chest from outboard shoulder to assembly (2) to the LH fitting and the nonadjust-
inner center of lap. to the LH center fitting.
able portion
e. Connect adjustable portion of seat belt
f. Locate the three existing cargo floor seat assembly (1) to the RH fitting and the nonailjust-
beTt fittings on the aft compartment floor at able portion to the RH center fitting.
station 124. 00.
Connect adjustable portion of seat-belt 3-13. WEIGHT AND BALANCE.
g.
assembly (5) to the RH fitting and nonadjustable
Record necessary weight and balance
portion to center fitting. a.
changes.
NOTE: All seat belt assemblies are to be
installed as illustrated in figure 3-4 and as NOTE: Refer to table 3-2 for applicable
noted on cloth identification labels attached weight and balance data for 369D Series
to each seat belt assembly. The two center helicopters and to table 3-3 for 3693 and
belts are installed with hooks down. 3693 Series helicopters.
Table 3-2. Weight and Balance Data 369D Helicopters
-501 Kit
Added +30.2 +93.5 t2824
Removed -32. 7 -1-108. 6 -3551
Net Change -2.5 t290.8 -727
Table 3-3. Weight and Balance Data 369E/F Helicopters
-503 Kit
Added ~31.2 +92.1 +2873
Seat Belts (2) -5. 1 t117.2 -598
Bench Seat -24. 7 till. 0 -2742
Net Change t1.4 -467

P\
NUT
:1 ROMMET
RIVET
CARGO TIE DOWN
FITTING 14 PLACES)
IT~B50 /.BELTASEMBLY STA. 1?IM O RIVtTTRB(NPIS~C_tSI
BELT ASSEMBLY
i,
r]l
j Ii
[~fi
SEATASSEMBLY
(4 PLACES)
i
~i
jI j
;i !Ii
j I
i i I i
I
ISTING CARGO FLOOR
ii SEAT BELT FITTINGS (3 PLACES
ii
I j i
/!ii4.0IN.
I ii /i i
ii/ i
~U !li j It
IIi
BELTASSEMBLY ,i
/ii ii ii
j II
:i
BELTASSEMBLY
O SEAT LOCATIONS
47-329
Figure 3-4. Seat Belt and Seat Assemblies Installation 369D/E/F Helicopters
Reissued 15 January 1985 3-73-8

CSP
071
Illusfrcr~ed Pcrrfs list

and
Maintenance Insfrucfions

FOR
LITTER INSTALLATION
Part No. 389D290170
USED ON MUCHES 500D (MODEL 3890) HELICOPTERS
Hughes Helicopters
COD102480 Issued 1 November 1980

IVI FG I
INTRO
Opt Eqpt Manual CSP-OI1
IN~EI1 LATEST CHANGED RAGEl, DE)llOr SURELJLDED RAGES.

IISV OF EF~ECTIVE PAGES SHE A8Tf RISK INDICATES RAGES CHANGED. ADDED. OR DELETED sV THE CURRENT CHANGE.
Page Issue
Title Original
A thruB.......... Original
CBlank Original
i,...,.......,., Original
ii Blank Original
FC1 Original
F-2 Blank.....,... Original
1-lthrml-29...... Original
1-30 Blank Original
2-1thru2-6 Original
3-1 thru 3-12,.,.., Original
CSP-OI1 Opt Eqpt Manual
use
revisions.
Hughes Helicopters

2/T7B
Originator
Address
Figure Number(s)
Remarks/Ptecommendations
B/C
RECORD OF REVISIONS
CSP-071
MFG REV

CSP-OI1 Opt Eqpt Manual Table of Contents
TABLE OF CONTENTS
Section Page
FOREWORD F-l
FI1. Purpose and Content of

this Manual........... F-l
F-7. Organization of Contents F-r
F-ll. Related Publications..... F-l
Revisions F-l
I ILLUSTRATED PARTS LIST
1-i. Scope and Contents...... 1-1

List
1-5. Illustrations I-1
2 MA~NTENANCE INSTRIJCTIONS.. 2-1

2-2. Scope 2-1
2-8. De~cription 2-1
2-8. Litterlnstallation 2-1
2-9. Replacement of Litter
Installation Components... 2-1
2-11. Inspectionof Litter
Installation 2-1
2-12. RepairofLitter
Installation 2-1
2-14. Bubble Door ~Installation 2-1
CSP-OI1 Opt EQpt Manual Table of Contents
TABLE OF CONTENTS
Section Page
2-15. General 2-1

2-17. Bubble Door Frame 2-1
2-L9. Bubble Door
Troubleshooting. 2-1
2-20. Attendant Seat
Installation 2-1
2-21. Lock Assembly 2-1
2-22. Stowage and Use of Litter
Kit Components........ 2-2
2-23. Stowageof Lifter Kit
Components. 2-2
2-25. Useof LitterKit
Components.......-. 2-2
2-27. Operationof Bubble
Doors. 2-6
3 INSTALLATION INSTRUCTIONS. 3-1
3-1. General Information..... 3-1

3-2, Scope 3-1
Installation 3-1
3-8, Reinoval of Helicopter
Equipment. 3-1
3-10. Installation of Litter Kit
Components. 3-2
3-12. Litter Assemblies 3-2
3-15. AttendantSeats 3-4
3-16, Installation of Vertical
Support, 3-4
3-18. Bubble Doors.......... 3-8
3-22. Replacementof Helicopter
Equipment. 3-8
3-24. WeightandBalance 3-8
iii
CSP-OI1 Opt Eqpt Manual Foreword
FORMIORD
F-l. PURPOSE AND CONTENT OFTHI_S Each section is organized to provide comprehen-
F-2. This manual supplements information con- or associated. (Procedures for each of these are
tained in Handbook of Maintenance Instructions presented in sequence as defined in Section 1,

Vol 1 (HMI) and 369D Illustrated Parts Catalog HMI Vol 1).
(IPC), and contains instructions for initial in-
stallation and continuing maintenance for the
Litter Installations. Weight and balance data is
for procuring replacement parts for the Litter F-10. This manual is for by operators of
use
Installations. the Model 36913 helicopter equipped with a Litter

Installation. Although this manual is a separate
F-3. APPLICABILITY. publication, it should be kept with HMI Vol 1,
HMI Vol 2, 369D IPC, and other handbooks
F-4. The Litter Installation is applicable for listed in Section 1, HNZI Vol 1 that form the
use on any Hughes 500D (Model 369D) helicopter. primary information file for the helicopter.
F-5, COMPATIBILITY OF COMBINED

OPTIONAL EQUIPMENT.

F-6. compatibility information on which
For
of HMI Vol 1 and 369D IPC as required to
combination at the same time, refer to Section 21,
HMI- Vol 1.
F-8. The contents of this manual is grouped into manual are made as defined in Section 1, HMI
sections as outlined in the Table of Contents. Vol 1.
F-1/F-2
SECTION 1
1-1. SCOPE AND CONTENTS. is exploded to the extent necessary to show parts
relationship for the complete Litter Installation
1-2. This illustrated parts list provides, by (fig. i-I).
means of text (parts lists)and companion illus-
trations, a complete parts definition of the
PN 369D 290170 Litter Installation manufactured
by Hughes Helicopters, Culver City, California.
1-8. The USABLE ON CODE column located at
NOTE the right-hand side of the group assembly parts
list pages indicates the effectivity of parts by
The illustrated parts list is organiz;ed and aircraft serialnumber. In many cases two differ-
presented in the same manner as the 369D ent parts are listed, one representing the original
Series Illustrated Parts Catalog (369D -IPC). installation and another representing the improved
(For information on use, refer to 369D IPC). replacement item. Alphabetic codes are used to
indicate the aircraft serial number applications
1-3. GROUP ASSEMBLY PARTS LIST. of a given part. When no USABLE ON CODE is
listed, items are understood to have full effec-
1-4. parts lists furnish information for
The tivity. The alphabetic codes used in this manual
procuring replacement parts for the Litter are listed and explained below:
Installations and shall not be used for any other
purpose. For information or procurement of
USABLE ON CODE AIRCRAFT
replacement parts, refer to 369D IPC.
LETTER EFFECTIVITY
1-5. ILLUSTRATIONS.
A -0940 and subsequent
each group assembly parts list. Each illustration B -0001 through -0939
1-1
ii
Q
13
23
n~ Is
tos7
9
It
12
17
a
19
22
15
16
21
24
16
r17-561-1A

1-2
CSP-OI1 Opt Eqpt Manual Section 1
3! 33
35
ii
~1
26
30s~
27
35
7 26
31 36
ze
2a Bfl:
26
27
14 29
I I
!A
s--~-O
,i
.11~ IROTATED
5
47-561-2B
1-3
FIG.
UNITS USABLE
NO. NO. ASSY CODE
1-1- 369D290170 LITTER KIT INSTL 1

-1 369D290249 DECAL 1
-2 369B6615-167 DECAL, LH 1
369B6615-168 DECAL, RH 1
-3 1 369B6615-169 DECAL, LH (Utilized on aircraft with light 1
color exterior)
369B6615-177 DECAL, LH (Utilized on aircraft with dark 1
color exterior)
369H6615-170 1 DECAL, RH (Utilized on aircraft with light 1
color exterior)
369116615- 178 DECAL, RH (Utilized on aircraft with dark 1
color exterior)
-4 369B6615-171 1 DECAL, LH 1
369B6615-172 DECAL, RH 1
-5 1 369B6615-173 1 DECAL, LH......................... 1
369H6615-174 1 DECAL, RH 1
-6 369H6615-175 DECAL 2
-7 369D292577-3 CARD, VNE 1
-8 369D292577-5 CARD, VNE 1
-9 3 69D292 577 -7 CARD, VNE 1
-10 369D292578-3 CARD, VNE 1
-11 369D292578-5 CARD, VNE 1
-12 369D292578-7 CARD, VNE 1
-13 369D290150-1 DOOR INSTL, LH (See fig, 1-2 for bkdn),,,,,, 1
369D290150-2 DOOR INSTL, RH (See fig, 1-2 for bkdn),,,,,, 1
-14 369D290230-501 PROPINSTL, REARDOOR, LH.,,,..,,,.. 1 A
(See fig, 1-5 for bkdn)
369D290230-1 PROPINSTL, REARDOOR, LH.,,.,,,,,,, 1 B
(For replacement order 369D290230-501)
369D290230-502 PROPINSTL, REARDOOR, RH,,,,,,,,,.. 1 A
3 69332 90230 -2 PROP INSTL, REARDOOR, RH 1 B
(See fig. 1-5 for bkdn)
-15 AN42B-C3A BOLT 2
-16 NAS1329H3-80L RIVNUT I 2
-17 NAS1333A3S10 PIN. 1
369D290170-11 1 STRAP ASSY 1
-18 SR18 I.. RING 1
-19 369D290170-9 1,, BUCKLE. 2
-20 369D290170-3 1,, STRAP, 1
369D290170-13 STRAP ASSY 1
-21 SR18 i,. RING i 1
-22 369D290 170-5 STRAP 1
-23 369D290227 1 BAG, SUPPORTARM STOWAGE........... 1
-24 369D290200 LITTERASSY(Seefig, 1-7forbkdn) 2
-25 369D290215 BRACE, SUPPORT ARM 4
-26 369D290190 ARM ASSY, SUPPORT (See fig, 1-9 for bkdn) 4
-27 SFSW1OF1ODS* SCREW 4
06BG
-28 SFSW 10F24DS* I SCREW Z
06BG
1-4
Opt EQpt Manual Section I
CSP-OI1
UNITS USABLE
FIG.
DESCRIPTION PER ON
INDEX PART
ASSY CODE
NO. NO.
RIVET. 4
1-1-29 MS204070AD4
BRACKET ASSY 2
369B6524-801
I.. RIVNUT 1
-30 A10K-75
369116524-463 1.. BRACKET I 1
-31
PANEL ASSY, FORWARD BULKHEAD AFT.... 1
36913290226
-32 369D290226-7 1.. ANGLE 1 4
369D290226-5 1.. TRIM.......... AR

-33
369D290226-3 PANEL ASSY 1
-34
SUPPORTINSTL, VERTICAL 1
-35 369D290171
369D290223 SEAT~STL, ATTENDANT 1
-36
1-5
~a
22 21
O
~7-988-1
Figure 1-2. Litter high door installation (sheet 1 of 2)
1-6
.G-,
c
O
O
U~ 3
I -I
ii
A k~;
:s
It
O O
~7-988-2
Figure 1-2. Litter high door installation (sheet 2 of 2)
1-7
Opt Eqpt Manual CSP-OI1
Section 1
FIG. UNITS USABLE

NO. NO. ASSY CODE
1-2- 369D290150-1 DOOR MSTL, LITTER HIGH REF

(See fig. 1-1 for NHA)
369D290150-2 DOORINSTL, LITTERHIGH REF
(See fig.. 1-1 for NHA)
-1 MS20470AD4 RIVET 1 4
-2 NAS~738B4 RIVET 1 16
369H92747-11 HINGE ASSY, UPPER, LH 1
369B92747-1 HINGE ASSY, UPPER, LH(For replacement... 1
order 369B92747-11)
369B92747-12 HINGE ASSY, UPPER, RH 1
3691192747-2 HINGE ASSY, UPPER, RH (For replacement... 1
order 3691192747-12)
-3 MS20427M3 I.. RIVET 2
-4 36982060 1.. CAM 1
-5 HS610CP3 132R* I.. BUSHING 1
190X190
-6 1 NAS~738B5 I RIVET 1 4
369B92034-11 HINGE ASSY, LOWER, LH I 1
369H92034-1 HINGE ASSY, LOWER, LH (For replacement... 1
order 369H92034-11)
369B92034-12 HINGE ASSY, LOWER, RH............... 1
369B92034-2 HINGE ASSY, LOWER, RH (For replacement 1
order 369B92034-12)
-7 MS2042 7M3 I RIVET 2
-8 369A2060 1.. CAM 1
-9 HS610CP3 132R* I.. BUSHING 1
190X190
-10 AN515C6R5 SCREW 30
-12 369B2038-45 COVER, LH 1
369H2038-46 1 COVER, RH 1
-13 369H2038-43 1 COVER, LH 1
369B2038-44 COVER, RH 1
-14 369B2038-41 1 COVER, LH 1
369B2038-42 COVER, RH. 1
-15 369H92732-3 1 COVER, LH 1
369B92732-4 COVER, RH 1
-16 MS20470AD4 I RIVET 1 14
-17 MLSP-B4 RIVET 1 8
-18 369H2048-27 1 LATCHINGSYSTEM, PASSENGERDOOR, LH.. 1
(See CSP-D-4 for bkdn)
369H2048-23 LATCHING SYSTEM, PASSENGER DOOR, LH.. 1
369B2048-28 1 LATCHING SYSTEM, PASSENGERDOOR, RH.. 1
369B2048-24 1 LATCHINGSYSTEM, PASSENGERDOOR, RH.. 1
(For replacement order 369H2048-28)
-19 AN960PD6 WASHER AR
-20 NAS623-3-6 I BOLT 15
-21 NAS623-3-22 BOLT 2
-22 AN960- 10L I WASHER 21
-23 NAS43PD3 -74 SPACER 2
1-8
FIG. UNITS USABLE

NO. NO. ASSY CODE
1-2-24 MS21042-3 NUT 2

-25 369D290151-501 1 ADAPTERASSY, BUBBLE AND DOOR....... 1
369D290151-502 ADAPTER ASSY, BUBBLE AND DOOR. 1
-26 MR4665 EXTRUSION AR
MR4~669 I EXTRUSION (Intrch MR4665). AR

-27 4508 SEAL AR
-28 369B92702-71 STRUCTURE ASSY, LITTERDOOR, LH...... 1
(See fig. bkdn)
1-8 for
369B92702-72 STRUCTURE ASSY, LITTERDOOR, RH...... 1
1-9
25
o I ill \III IEl ~/I
oP.2328
32
30~
dl -35
31 4.
1
a
30 8
29
15
36 20
b
i
12 1
14
oll/
18
13
B
11 17
10 -I
o
i
O
Bd~
3
~7-578A
Figure 1-3. Bubble and door litter kit adapter assembly

1-10
Secton 1
CSP-OI1 Opt Eqpt Manual
UNITS USABLE
FIG.
DESCRIPTION PER ON
INDEX PART
ASSY CODE
NO. NO.
1-3- 369D290151-501 ADAPTER ASSY, BUBBLE AND DOOR, LITTER.. REF
KIT, LH (See fig. 1-2 for NHA)

369D290151-502 ADAPTER ASSY, BUBBLE AND DOOR, LITTER.. REF
KIT, RH (See fig. 1-2 for NHA)

1
-1 1 369D290267-3 1 DECAL, INSTRUCTION, LH(Utilizedon......
aircraft with light color exterior)
1
369D290267-5 DECAL, INSTRUCTION, LH(Utilizedon.....
aircraft With dark color exterior)
1
369D290267-4 1 DECAL, INSTRUCTION, RH (Utilized on
aircraft with light color exterior)
1
369D290267-6 1 DECAL, INSTRUCTION, RH (Utilized on
aircraft with dark color exterior)
-2 1 369D290151-1 1 ADAPTER ASSY, LH (See fig. 1-4 for bkdn) 1
369D290151-2 ADAPTER ASSY, RH (See fig. 1-4 for bkdn) 1

MS20470B3 RIVET 4
-3 ...............I
NAS1738B4 i RIVET 2
-4 .................I
NAS620A3 I WASHER 4
-5
DOORLOCK, LH........... 1
-6 369D290266-5 CAP, BUBBLE
BUBBLE DOOR LOCK, LH........... 1
369D290266-3 CAP,
1
369D290266-6 CAP, BUBBLE DOOR LOCK, RH...........
1
369D290266-4 CAP, BUBBLE DOOR LOCK, RH...........
1
-7 369D290250-3 CAP, BUBBLE DOOR LOCK, LH...........
1
369D290250-4 CAP, BUBBLE DOORLOCK, RH...........
NAS1398M-4 I RIVET 2
-8
SCREW 2
-9 NASGO 1-10P
RIVET 1
-10 MS20470B3
2
-11 AN960PD8 I WASHER
-12 NAS620A5L WASHER 1
-13 HS4105-13 WASHER AR

NUT 2
-14 MS2 1042L06
LH. 1
-15 369D290265 PLATE, LOCK,
RH................ 1
369D290264 PLATE, LOCK,
RIVET 4
-16 NIS20470B4
NAS620A5L I WASHER AR
_17
LH............... 1
_18 369D290263-1 PLATE, LOCK,
RH............... 1
369D290263-2 PLATE, LOCK,
RIVET. 6
-19 MS20470B3 I
I WASHER 6
-20 NAS620A3
1
-21 3 69D2 90169 STRIP, RUB
RIVET. 4
-22 MS20426AD4
4
-23 NAS620A5 I WASHER
1
-24 369D290164 HANDLE, DOOR.........
SEAL 1
-25 369D290151-11
MS20470B4 I RIVET. 48
-26
I WASHER 48
-27 NAS620A5
HINGE. 1
-28 369D290157
1
369D290152-3 WINDOW ASSY, LH...........
1
369D290152-4 WINDOW ASSY, RH...........
71
-29 MS20470B4 I.. RIVET
WASHER 142
-30 NAS620A5
1
-31 369D290156-3 RETAINER, LH...........
1
369D290156-P 1.. RETAINER, RH...
1-11
FIG. UNITS USABLE

NO. NO. ASSY CODE
1-3-32 369D290156-5 1.. RETAINER, LH 1

369D290156-6 1 RETAINER, RH 1
-33 369D290156-7 1 RETAINER, LH 1
369D290156-8 RETAINER, RH 1
-34 369D290156-9 1 RETAINER, LH 1
369D290156-10 1.. RETAINER, RH 1
-35 369D290155-3 1.. WINDOW, LH I 1
369D290155-4 WINDOW, RH I 1
-36 369D290154-3 1.. BUBBLE, LH 1
369D290154-4 1.. BUBBLE, RH 1
1-12
13
17
,32
f
o 1 111 23
2 111 1 ill 11~9
5
4
6 I O
ea,
ol I //D
q7-579-1
Figure 1-4. Bubble and door adapter assembly (sheet 1 of 2)
1-13
Section 1 Opt Eqpt Manual CSP-OI1
a
ROTATED 19
21
1115 11) i2
s
O
~9"-
lo
;:1
26 O 21
47-579-2
Figure 1-4. Bubble and door adapter assembly (sheet 2 of 2)

1-14
FIG. UNITS USABLE

NO. NO. ASSY CODE
1-4- 369D290151-1 ADAPTER ASSY, BUBBLE AND DOOR, LH 1

369D290151-2 ADAPTER ASSY, BUBBLE AND DOOR, RH 1
-1 3 69D2 90151- 9 1 SEAL 2
-2 HS4727-3-3 SCREW 4
-5 221[(1-02 NUT 4
-6 MS21042-3 I NUT 2
369D290260-1 1 LOCKASSY, DOOR, LH................ 1

369D290260-2 LOCKASSY, DOOR, RH................ 1
-7 M8163562-34 1.. PIN 2
-8 369D290258-1 HANDLE, LH 1
3 69D2 90258 -2 1 HANDLE, RH I 1
-9 369D290254 SCREW. 2
-10 1MS3 5335- 67 1 LOCKWASHER .....................I
2
-11 AN960C516L I.. WASHER. AR
-12 MS2 1045L5 1.. LOCKNUT. 2
-13 3 69D2902 55 -3 BOLT, LH 1
369D290255-4 1.. BOLT, RH................. 1
-14 C0480-051-15005 1.. SPRING 2
C0480-051-1500MI.. SPRING 2
(Intrch C04801-051-15005)
-15 MS28775-011 I.. O-RING 2
-16 369D290259 1.. HOUSING 2

-17 369D290151-5 1 SEAL 1
-18 MS20426B3 I RIVET. 10
-19 369D290151-7 1 SEAL 1
-20 369D290165 1 STRIP, DOOR ADAPTER 1
-21 369D290166 GUIDE. 1
-22 MS20470B3 I RIVET. 28
-23 NAS620A3 WASHER 10
369D290168-1 COVER ASSY, LH 1
369D290168-2 COVER ASSY, RH. 1
-24 MS20426AD3 I.. RIVET AR
-25 369D290168-11 1.. FILLER 1
-26 369D290168-13 1.. PIN 1
-27 369D290168-15 1.. PIN 1
-28 369D290168-3 1.. HINGE, HALF, LH. 1
369D290168-4 HINGE, HALF, RH. 1
-29 369D290168-5 1.. MINCE, HALF, LH. 1
369D290168-6 1.. HINGE, HALF, RH. 1
-30 369D290168-7 1.. HINGE, HALF, LH. 1
369D290168-8 HINGE, HALF, RH. 1
1
-31 3 69D2 90168 9 1 HINGE, HALF
-32 369D290153-3 1 ADAPTER, DOOR, LH. 1
369D290153-4 1 ADAPTER, DOOR, RH. 1
1-15
;I-
2 4,
9
I
_L ~2
7 11
8
YC
,~"r O
:cc~
"I
47-562
Figure 1-5. Prop installation
1-16
FIG. UNITS USABLE

NO. NO. ASSY CODE
1-5- 3 69D2 90 23 0 50 1 PROP INSTL, REAR DOOR, LITTER WT, LH REF A

I-lfor NHA)
(See fig.
369D290230-1 PROP INSTL, REAR DOOR, LITTER KIT, LH REF B
(See fig. I-lfor NHA)
369D290230-502 PROP INSTL, REAR DOOR, LITTER WT, RH REF A
369D290230-2 PROP INSTL, REAR DOOR, LITTER KTT, RH REF B
-1 MS16228-5C NUT 2
-3 369D290247 1 SPRINGASSY, GAS I 1 B
-4 MS90354-0502 1 RIVET. 7
-5 369D290231-3 1 BRACKET ASSY 1
-6 111390354-0502 RIVET. 8
-7 369B290231-9 STIFFENER, LH .....................I
1
369D290231-10 STIFFENER, RH............. I 1
-8 369D290231-12 CLIP. 1
-9 369D290231-11 CLIP. 1
-10 369D290231-13 DOUBLER 1
-11 369D290245-3 1 COVER, LH 1
369D290245-4 1 COVER, RH 1
1-17
21
ij 30
3 1 1 4 23
25
7 24
rP
O 2 3
47-563-1
Figure 1-6. Attendant seat installation (sheet 1 of 2)

1-18
34
37
32
1 33
10 1
d
47-563-2
Figure 1-6. Attendant seat installation (sheet 2 of 2)
1-19
FIG. UNITS USABLE

NO. NO. ASSY CODE
1-6- 369D290223 SEAT INSTL, ATTENDANT LITTER KIT....... REF

-1 I NAS1333AS10 PIN. 4
369D290221 SEAT ASSY 2
-2 MS24665- 170 1.. PI[N 2
-3 MS20392-3 C31 I PIN 2
-4 AN960-416C I.. WASHER .........................I
2
-5 NAS133 A3 S10 I PIN 2
-6 MS20615-4M RIVET 4
-7 MS20470AD4 I.. RIVET 2
-8 NAS561-4-14 I.. Pn\T 2
-9 369B6557-35 1.. PIN, LOCK 2
-10 LC022C9 I.. SPRING 2
-11 NAS1351C08LN12 I.. SCREW ..........................I
2
-12 369B6557-33 1.. HOUSING 2
-13 369B6557-37 FITTING .........................I
2
-14 369B6557-17 1.. TUBING 2
-15 369B6557-19 TUBING 2
-16 NAS 1304-4 1.. BOLT ...........................I
4
-17 NAS620-416L I.. WASHER. 4
369D290219 CUSHION ASSY 1
-18 SS-58698 1... TEENUT 4
-19 369D290219-9 1... COVERING, VINYL (BOTTOM)......... AR
-20 369D290219-7 1... COVERING, VNYL(TOP) AR
-21 369D290219-5 1... CUSHION 1
-22 369D290219-3 1... PLATFORM 1
-23 3 691)2 902 18 1 FITTING .........................I
4
-24 369D290217-3 1.. FITTING, LH.............. 1
369D290217-4 1.. FITTING, RH I 1
-25 3 69D2 90216 1 TUBE. 2
-26 HS51248-K1110 I.. PLUG ...........................I
2
-27 MS20426A4 RIVET. 6
-28 369D290223-3 DOUBLER 6
-29 369D290220-13 BELT ASSY 1
-30 3 69D2 902 20- 11 BELT ASSY 2
369D290222-1 ASSY, LH
BACKREST 1
369D290222-2 BACKRESTASSY, RH 1
-31 369D290222-7 1.. TAPE, HOOK, LH 1
369D290222-9 TAPE, HOOK, RH 1
-32 3 69D2 90222 5 1 COVERING, VINYL AR
-33 369D290222-3 1.. CUSHION, LH 1
3693~290222-4 1.. CUSHION, RH 1
-34 369D290233-9 TAPE, PILE ........................I
2
-35 3 69D2 9023 3 -8 TAPE, PILE 1
-36 369D290233-7 1 TAPE, PILE.......... 1
-37 3 69D2 90223 5 TAPE, PILE 1 2
-38 NAS1919M04-2 I RIVET. 12
-39 369A2508-191 BRACKET 2
1-20
I
0 2
1 11
7/ -19
47-526
Figure 1-7. Litter kit assembly
1-21
FIG. UNITS USABLE

NO. NO. ASSY CODE
1-7- 369D290200 LITTER KIT ASSY (See fig. I-lfor NHA) REF
-1 MS2 10833~4 1 NUT 8
-2 AN960C416 WASHER 8
-3 NAS1304-25 BOLT 8
-4 369D290228 WASHER 16
-5 369D290209 HANDLE 4
-6 MS903 53 -06 RIVET. 8
-7 369D290207 1 HINGE. 2
-8 MS20470AD6 RIVET. 6
-9 MS20470AD4 I RIVET. 26
10 H4 62 -3 LATCH 2
-11 3 69D290229-3 1 BRACKE T 2
-12 369D290229-5 BRACKET 2
-13 369D290201 1 LITTER, HALF 2
-14 M324665-153 PIN, COTTER 8
-15 MS20392-2C79 PIN. 8
-16 AN960- 10L WASHER 8
-17 369B92723-5 BELT ASSY 4
-18 369B92723-3 BELT ASSY 4
-19 896 1 EXTRUSION 8
1-22
~7t-
1111 B
2 ii I
117-999-1
Figure 1-8. Litter door structural installation (sheet 1 of 2)
1-23
12 .4
p, iii
i
117-999-2
Figure 1-8. Litter door structural installation (sheet 2 of 2)

1-24
CSP-OI1 Opt Eqpt Manual Section 1.
FIG. UNITS USABLE

NO. NO. ASSY CODE
1-8- 369H92702-71 STRUCTURE INSTL, LITTER DOOR, LH....... REF

(See fig. 1-2 forNHA)
369B92702-72 STRUCTURE INSTL, LITTER DOOR, RH. REF
-1 I MLSPB4 I RIVET. AR
369B92702-23 RETAn\TERASSY, WINDOW, LH........... 1
369H92702-24 1 RETAINERASSY, WINDOW, RH........... 1
-2 369B92702-27 1.. CLIP 2
-3 369H92702-29 1.. CLIP 24
-4 369B92702-55 1.. CLIP 2
-5 369B92702-35 1.. RETAINER 1
-6 MS20426AD3 I RIVET. AR
-7 MS21059-3 NUTPLATE 15
-9 NAS697C06M NUTPLATE 3
-11 369B92702-15 1 CHANNEL, LH 1
369H92702-16 CHANNEL, RH 1
369B92702-31 ZEE ASSY, LH 1
369B92702-32 ZEE ASSY, RH 1
-12 369B92702-49 1.. STRIP, BACKUP, LH................. 1
369B92702-50 1.. STRIP, BACKUP, RH................. 1
-13 369B92702-59 1.. ZEE, LH 1
369H92702-60 1.. ZEE, RH I 1
-14 369B92702-41 1.. STRIP, BACKUP, LH................. 1
369B92702-42 1.. STRIP, BACKUP, RH................. 1
-15 369B92702-47 1.. STRIP, BACKUP 2
-16 369B92702-51 1.. STRIP, BACKUP, LH................. i
369B92702-52 1.. STRIP, BACKUP, RH................. 1
369B92702-11 1 ZEE ASSY, LH 1
369B92702- 12 ZEE ASSY, RH 1
-17 369H92702-43 1.. STRIP, BACKUP, LH...............,. 1
369B92702-44 1.. STRIP, BACKUP, RH................. 1
-18 369B92702-13 1.. ZEE, LH I 1
369B92702- 14 ZEE, RH 1
1-25
10 23
fiSI
30
1_-
12
i.
22
a 22 I~
27
26
ii Co
t j
32
33
22
Ir 31
15
1
2
19 16
17
t
34 31
16.
I/
27
~-1
is
29
I28
47-527
Figure 1-9. Litter kit support arm assembly
1-26
CSP-071 Opt Eqpt Manual Section I
FIG. UNITS USABLE

NO. NO. ASSY CODE
1-9- 369D290190 ASSY, L~TTER

ARM XIT SUPPORT I REF
-1 4054 1 THUMBSCREW 2
-2 AN960C416L I WASHER 2
-3 MS9048-007 PIN, SPRING 1
-4 369D290198 1 PIN. 1
-5 MS20470AD3 I RIVET ............................I
2
-6 NAS42HT3-8 SPACER 2
-7 53433-1 RECEPTACLE 1
369D290243 HANDLE ASSY 1
-8 AN3 16C-10 I.. NUT. 1
-9 53433 1.. PIN I 1
-10 NAS1190-04P8 I.. SCREW ..........................I
2
-11 NAS671C4 I.. NC~T. 2
-12 369D290244 1.. GRIP, HANDLE 2
-13 369D290184 1.. HANDLE ......................,..I
L
-14 MS9048- 178 PIN, SPRING 2
369D290211 BRACKET ASSY, ROLLER 1
-15 MS51975-17 I.. SCREW. 1
-16 AN960C616L I.. WASHER .........................I
2
-17 369D290212 1.. ROLLER .........................I
1
-18 MS9390-160 I.. FIN 2
-19 369D290213 BRACKET, ROLLER 1
-20 369D290194-11 RCD I
-21 C0720-081-1250 SPRING L
-22 369D290 193 ROLLER 3
369D290228- LUG ASSY 1
-23 NAS623-2-2 I.. SCREW ..........................I
1
-24 AN960C8 I.. WASHER .........................I
1
-25 369D290210 1.. PLUNGER ........................I
1
-26 NAS602-12P I.. SCREW. 4
-27 NAS620C8 I.. WASHER 1 8
-28 MS2 10B3C08 i.. NUT. 4
-29 369D290242 1.. FITTING .........................I
1
-30 369D290195 1.. LUG I 1
-31 MS20470AD3 I RIVET. 4
-32 369D290197 SPACER 2
-33 9245 CATCH 1
-34 369D290 189 1 ARM, SUPPORT. 1
1-27
a-~24
Oi
25 24
\P B
,O
i~? ~CbS,10
i,";
11
o
Is
r4\\ a/lJ
i"
8 18 19
BP 5 ~L
0 7 20
n 6
47-997
Figure 1-10. Vertical canted station 78. 50 Litter kit support installation
1-28
CSP-071 Opt Eqpt Manual CSP-OI1
FIG. UNITS USABLE

NO. NO. ASSY CODE
1-10- 369D290171 SUPPORT INSTL, VERTICAL, CANTED STA.... REF

78. 50 LITTER KIT (See fig. 1-1 for NHA)
-1 HS734-19 BOLT 8
-2 AN960-416L WASHER 8
369D290180-1 SUPPORT
ASSY, L~H 1
369D290180-2 SUPPORT ASSY, RH 1
-3 1 369D290180-3 1.. CHANNEL, LH 1
369D290180-4 1.. CHANNEL, RH 1
-4 369D290180-5 1.. PLATE, LH 1
369D290180-6 1.. PLATE, RH I 1
-5 MS20470AD4 I RIVET. AR
NAS 1398D4 RIVET (IntrchMS20470AD4) AR
-6 MS2042 6AD3 RIVET. AR
NAS1399D3 RIVET (IntrchMS20470AD4) AR
NAS1398D3 RIVET (Intrch MS20426AD3) AR
-8 MS20615M3 I RIVET AR
NAS1738M3 I RIVET (Intrch MS20615M3) AR
-9 1 MS20426AD4 I RIVET. AR
NAS1399D4 RIVET (Intrch MS20426AD4) AR
369D290182 DOUBLER ASSY 2
-10 MSR042 6AD3 I RIVET 8
-11 MS21077-4 I,. NUTPLATE .......................I
4
-12 369D290182-3 1.. DOUBLER ........................I
1
-13 NIS20615M4 RIVET. I AR
NAS1738M4 RIVET (Intrch MS20615M4) AR
NAS173 9M3 I RIVET (Intch MS20470AD3) AR
-15 369D290181-1 CHANNEL ASSY, LH 1
369D290181-2 CHANNEL ASSY, RH 1
-16 MS20426AD3 I.. RIVET 8
-17 MS2 1077-4 1.. NUTPLATE .......................I
4
-18 369D290177 SPACER 2
-19 369D290178 1 SPACER 2
-20 369D290175 SPACER 2
-21 3 69D29017 6 SPACER 2
-22 369D290179 SPACER........... 2
-23 369D290174-1 1 ANGLE, LH. 1
369D290174-2 1 ANGLE, RH 1
-24 NAS 13 98D4 RIVET. AR
NAS1738E4 I RIVET (IntrchNAS1398D4) AR
-25 369D290173 COVER, LH 1
-26 369D298 172 1 COVER, RH 1
1-29/1-30
SECTION 2
2-1. GENERAL INFORMATION. c. Inspect litter safety belts for worn or frayed
condition and loose stitching. If any doubt exists
2-2. SCOPE. as to belt strength, pull test with a 1500-pound
test load as specified in HMI Vol i. Replace
2-3. This section provides description and main- unserviceable belts.
tenance information for the litter kit installation.
This information is intended for user-level (field) 2-12. REPAIR OF LITTER INSTALLATION.
service and repair.
2-13. Perform tubular weld repairs and repair
2-4. REFERENCE DATA. damaged sheet metal according to instructions in
FAA AC 43. 13-1, Aircraft Inspection and Repair.
2-5. Information pertaining to helicopter struc-
tural components which interface with the litter 2-14. BUBBLE DOOR INSTALLATION.
kit installation is in the Structural Repair Manual
(369D SRM). Information pertaining to standard 2-15. GENERAL.
helicopter equipment is in HMI Vol 1 and
369D IPC. 2-16. The bubble door installation consists of
a door frame complete with hinges, door latch-
2-6. DESCRIPTION. ing mechanism, and a "bubble" window config-
uration. The bubble window, used with litters
2-7. The litter kit installation consists of two installed, is installed on the door frame with an
litters, two support assemblies and four special adapter assembly.
arm supports. The support assemblies are
mounted on the aft side of canted bulkhead station 2-17. BUBBLE DOOR FRAME.
78. 50. The arm support assemblies slide into
notches provided in the support assemblies. The 2-18. The bubble door frame consists of a com-
litters slideacross rollers provided in the arm plete door frame assembly with automatic latching
supports and are secured in place with locking mechanism. Refer to HMI Vol 1 for inspection
mechanisms. Additional equipment includes two and maintenance of the door frame, hinges, and
bubble doors and prop assemblies for opening bub automatic latching mechanism.
ble doors. Two attendant seats which mount to
/2-19. BUBBLE DOOR TROUBLESHOOTING.
the aft cargo compartment floor and bulkhead are
(Refer to table 2-1.
also provided.
2-20. ATTENDANT SEAT INSTALLATION.
2-8. LITTER INSTALLATION. (Refer to figure 1-6.)
Inspect seat and support assemblies and
a.
2-9. REPLACEMENT OF LITTER INSTALLA-
att~ichinghardware for security of installation,
TION COMPONENTS.
distortion, cracks, breaks, corrosion, or other
dam age.
2-10. See figure 1-1 and remove or install suf-
ficient attaching hardware for individual com- Inspect backrest assembly, pile tape,
b.
ponent replacement or repair. 1
cushion assembly, belt assemblies, doublers,
and attaching hardware for excessive wear,
damage, and security of installation.
2-11. INSPECTION OF LITTER INSTALLATION.;
2-21. LOCKASSEMBLY. (Referto figure 1-4.)

a. Inspect litters and supporting framework
and other
a. Inspect housing (15), lock handles(7), sliding
for cracks, corrosion, deformation, boT~t (12), and associated hardware and attach
visible damage.
parts for security of installation, cracks, breaks,
corrosion, or other damage.
b. Inspect pivot points and attaching hardware
forwear and positive locking. I b. Inspect lack assembly for proper function.
2-1
Table 2-1. Bubble door troubleshooting
Door will not open Improperly operating (stuck) Clean and lubricate latching mechanism.
latching mechanism If this does not correct, check part
functioning; disassemble mechanism and
replace any damaged parts. Refer to
figure 1-7.
Defective door prop Replace door prop. (Refer to figure 1-2.)
Door will not close Defective door prop Replace door prop.
Defective hinge assembly Clean and lubricate. If this does not

correct, disassemble and replace
defective parts.
Door is difficult to Misaligned door and adapter Adjust.

open and close assembly
Door will not open/close Jammed latching mechanism Check component functioning; clean and
lubricate mechanism; replace defective
parts.
2-22. STOWAGE AND USE OF LITTER I<IT h. Fold attendant seats against aft bulkhead and
COMPONENTS. secure using straps (20 and22, fig. 1-1) mounted
on bulkhead.
2-23. STOWAGE OF LITTER KIT COMPONENTS.
i. For stowage of litters and stowage bag,
2-24. The following operations are required for refer to figure 2-4 and perform the following:
proper stowage of litter kit components.
(1) Position litters aft of eyebolts on cargo
a. Stow litters by disengaging latches located floor.
on underside of litter.
(2) Place stowage bag on top of litters with
b. Place all buckle and strap assemblies inside support brack compartment aft of litters.
fir~st litter and fold litter in half.
(3) Place two support arm compartments on
Second litter is stowed by placing buckle and

c. top of litters.
strap assemblies outboard of litter.
(4) Ensure proper placement of litters and
d. Fold second litter in half and place first stowage bag and secure components using strap
liti~er on top of second litter. (Refer to figure 2-1.) assemblies mounted on bulkhead and cargo floor.
e. Secure buckle and strap assemblies as 2-25. USE OF LITTER KIT COMPONENTS.
shown in figure 2-2.
2-26. following operations are required for
The
f. stowage bag (23, fig. 1-1) on flat
Place proper of litter kit components.
use (Refer to
surface. Slide support arm assemblies (26) and figure 2-5 and perform the following):
support braces (25) into individual compartments
of stowage bag. Refer to figure 2-3. Secure flaps
on stowage bag.
yzn~
g. Stow attendant seat assemblies (36, fig. 1-1) Litter doors are spring-loaded. Stand clear
by releasing locking pins (9, fig. 1-6) located at when opening to avoid contact from the door-
bottom of seat supports. opening action.
2-2
CSP-O?1 Opt Eqpt Manual Section 2
-~%u
S
mrors
~lhr -srcono
tgt~tR:i
17989
Figure 2-1. Litters in position
ITRAP
E[UR~O
.2
ui-src
Figure 2-2. Litters secured
2-3
Opt Foot Manual CSP-OI1
Semen 2
BRRLIS--_
i;. ~ui-
$Yiz
SUPPORT RIU~ AIEnLIES

(LO(KID POII~ION)
UI-911
Figure 2-3. Stowage bags and components
nrrtlos~
STOWA6~ BR6 m0
~onpaNars
srlw arrtnsLltr
KI~ STWIP
IISSII(BLIES
ui
BRLCLI
Isrouto,
11-992
Figure 2-4. LLtter components stowed
2-4
CSP-O?1 Opt Eqpt Manual Section 2
SUPPORT RWI41SLnBLIIB
r" -RRntis
i -iinlou
i- pmlllaii
LIIFR
iii-111
Flb~re a-r,. Litter Bit cumgononts inutalled
oiai
mroi liahllli-
~il
oaoii (CPIHI
V)-CJU
Flyre 2-6. nubble duer latch decnl
2-5
a. Open bubble doors to gain access to stowed 1. Lift litter and patient and position on sup-
litter components. port arm. Slide litter across rollers to engage
latching on support arm.
b. Release strap assemblies securing stowage
bag and litters to cargo floor. if. With litter and patient in position, rotate
handle to engage latching pin and secure litter in
c. Remove stowagebagandlitters. Place place.
stowage bag on flat surface.
NOTE
d. Open flaps stowage bag and remove
on sup-
port arm assemblies and support braces. If handle does not latch, rotate counter-
clockwise to loosen or clockwise to tighten.
e. Position support arm assemblies in slots
provided in bulkhead mounted support, i. Disengage stowed attendant seat straps and
atf~gch seats to cargo floor with latching mech-
f. Position support braces on underside of anism on bottom of seat support.
support arm so that braces form a cross. Secure
braces by tightening thumbscrews on support 2-27. OPERATION OF BUBBLE DOORS.
arms.
a. Locate latch handle on forward side of

ff. Ensure handles on arm assemblies are in litter doors.
the unlocked position.
b. Open bubble doors by rotating handle out-
4 Disengage buckle and strap assemblies board, then pulling handle forward. Bubble door
securing litters. Unfold litters and engage will swing open. (Refer to figure 2-6 for location
latches on underside of litters. of decal.
i. Place litter patient on litter and secure c. Close bubble doors by pushing on bubble,
buckle and strap assemblies, thus engaging the latching mechanism.
2-6
SECTION 3
3-1. GENERAL INFORMATION. 3-6. PREPARATION FOR INSTALLATION.
3-2. SCOPE. 3-7. Preparation for installation of the litter kit

includes the following:
3-3. Procedures in this section may be per-
formed at the operators discretion and provide _a. Identify all components of litter kit including
complete instructions for initial installation of the attaching hardware and components removed to
litter kit. These procedures are additional to gain access to work areas. Protect all compo-
those for maintenance of the litter kit components. nents from damage and foreign matter.
Reference is made in the Instructions to Appli-
cable Data in the HMI Vol 1 to accomplish _b. Check all electrical switches for OFF posi-
installation of Litter components. tion and turn BATT-OFF-EXT switch to OFF.
3-4. REFERENCE DATA. 3-8. REMOVAL OF HELICOPTER EQUIPMENT.
3-5. Table 3-1 lists consumable materials and 3-9. Before litter kit components are installed,
expendable items required for installation. Items a limited number of existing items must be
listed in the consumable materials and expendable removed from the helicopter. Refer to HMI
items table are recommended items and are of a Vol 1 and perform the following:
commercial nature that should be procurable
locally. Alternate, but equivalent, items are a. Remove crew and passenger compartment
acceptable. seats.
Commercial Product(2)
Item
(1)
No. Material Specification No. Name/No. Manufacturer
1. Adhesive, epoxy, MIL-A-52194 Scotch-Weld 3M Co., St. Paul, Minn.

non-structural EC 1838
(Parts A& B)
MIL-A-8623 A 1177B B. F. Goodrich
2. Grease 130A Lubriplate Mfg.

3. Solvent, dry P-D-680 (3)
cleaning
4. Sealant, polymer, PR 1221, Products Research and Chemical
non- structural Class B-2 Corp., Burbank, CA

specifications and standards. The prefix symbols are defined as
follows: AMSAmerican Material Standard;MS Military Standard; MIL military
specifications; single, double or triple alpha prefix of the same letter federal speci-
fication; AN Air Force-Navy aeronautical standard; NAS National Aerospace Standard.
the same type with the listed specification number cannot be determined.
3-1
b. Remove the following crew compartment i. Deburr drill holes and clean up drill chips.
trim panels as required: Install eyebolts (15, fig. 1-1) using rivnuts (16).
(1) Controls tunnel cover i. Locate strap assemblies and secure to eye
bolts.
(2) Shoulder beam
(3) Left and right bulkhead panels _k.

Locate strap assembly and existing bracket
onaft bulkhead (BL 3. 99 approximately). Slide
(4) Left and right lower aft panels.
metal ring into position and secure using pin (17).
c. Remove the following passenger compart-

Locate shoulder straps (20, 22) and seat
ment trim panels as required:
be~ts (19). Secure straps and belts to existing
brackets.
(1) Forward bulkheadpanel
(2) Left and right door panels m. Locate stowage bag (23), braces (25), and
arm assemblies (26). Place stowage bag on flat
(3) Floor carpeting and floor pan.
surface and slide braces and arm assemblies into
doors, compartments provided in stowage bag. Secure

d. Remove passenger compartment
flaps on stowage bag.
3-10. INSTALLATION OF LITTER KIT
_n. Install V,, cards as required.
COMPONENTS.
3-12. LITTER ASSEMBLIES.

3-11. The litter kit is
shipped with as many
parts assembled as possible; however, certain
3-13. The litter kit contains two Litter assem-
items require assembly at installation. Figures blies. The litter assemblies consist of two
1-1 thru 1-10 show major components of the
litter kit. Detail items listed in these figures latches, four belt assemblies, and four handles.
The individual litters are hinged in the center to
are to be used for ordering replacement parts as
accomplish stowage. The two latches are located
required. Detailed instructions, alongwith the right and left hand side of the litters, and
on
illustrations, follow for components that require are used to secure the litter in a flat position.
assembly or installation to complete litter kit
The four seat belts, located two on each litter
installation.
half, are used to secure the litter patient in place
on the litter. The four handles, located on the
a. Positiondecals(g, fig. 1-1). Cleanmount-
outboard sides of the litter, are used to lift and
ing surface, remove protective backing from
decals and install. transport the litter to the helicopter.
3-14. The following operations are required to

b. Positiondecals (3) asrequired. Clean
install the litter assemblies. (Refer to the figures
mounting surface, remove protective backing
call for in the below operations.
fromdecals, and install,
a. Remove litter assemblies (24, fig. 1-1)
c. decals, 1, 4, and 5). Clean mount-
Position from stowed position.
ing surface, remove protective backing from
b. Disconnect belt assemblies (17 and 18,
decals, and install.
fig. 1-7).
d. Locate brackets (31) and mark rivet holes c. Remove one litter and place on flat surface.
as shown in figure 3-1, view A.
d. Open litter and secure in flat position using
Drill rivet holes as required.
e. Deburr rivet
latches (18, fig. 1-2).
holes and clean up drill chips. Place litter patient litter
on assembly and
fasten belt assemblies (17 and 18, fig. 1-7) to
f. Position brackets (31, fig. 1-1) and install secure patient in place.
using rivets (29).
f. Using handles (5), lift litter, and slide
across arm assemblies (26, fig. 1-1).
g. Locate and install panel (34) using screws
(27 and 28). ff. Rotate handle (5, fig. 1-7) on arm assem-
bly and lock litter in position.

4 Locate and drill holes in cargo floor as
shown in figure 3-1, view A. h. Perform steps c. through_g. for second
litter.
3-2
DECAL
VERTICAL
SUPPORT
6,80 ,25
I I
I I
i i II NOTE(1)
4,00 I I
I
I
0,00
II i
111 1 I i
111 1 I I
III
19,00 1 I
111 1 I C-J I II /NOTE(1)
i I NOTE 1 AND 2 WL 22.30
I III
II Jf---~-----19, 35
I NOTE(1)
I I BL 0,00
i i I I DRILL ,220/,226 DIA
CL SHIP HOLES THESE LOCATIONS
NOTE(Z)
INSTALL BRACKETS AND
CARGO FLOOR
RIVETS THESE LOCATIONS
STA
102,23
117-980
Figure 3-1. Litter kit installation
3-3
Section 2 Opt Eqpt 1Vlanual CSP-OI1
3-15. ATTENDANT SEATS. c. Predetermine and mark all existing rivets

that require removal. (Refer to figure 3-3.)
%AUT ION
d. Using adrill motor and proper drill sizes,
drill out all existing rivets as required.
Use care in drilling through cargo floor: do
not puncture fuel cells. A portion of the existing structure must be
modified before installation of supports can be
a. Remove fuel cell access panels, and tem- accomplished. (Refer to figure 3-3, view D.)
porarily install backing material to protect fuel
cells when drilling. Verify removal of all existing rivets and
modification of structure.
b. Locate existing supports as shown In figure
3-~, view A. Using supports (14 and 15, fig. 1-6) ff. Locate channel assembly (3, fig. 1-10).
as templates, mark rivet holes. Position channel assembly in place and drill pilot
holes using existing rivet patterns. Cleco channel
c. Drill and deburr rivet holes. Install anti- in place.
chafing tape on rivets inside fuel cell compartment.
h. Locate spacer (21) and position in place.

pile tape (34, 35, 36, and 37). Refer
Locate Drill pilot holes as required and cleco in place.
to figure 3-2, view B and install tape as shown.
i. angle (23) and spacer (21). Position
Locate
e. Install back rest assembly (31 thru 33). angle and spacer in
place and drill pilot holes
through angle, spacer and channel assembly.
f. (28, fig. 1-6). Using
Locate doubler Cleco in place.
doublers templates, mark rivet holes as
as shown
in figure 3-2, view C. Locate spacer(l8, 19, and 22). Position
spacers in place and drill pilot holes as required.
~ff. Drill and deburr rivet holes. Position belt Cleco spacer in place.
assembly (29 and 30) and doublers. Install with
rivets (27). k.
Verify proper positioning of all components:
channelassembly, spacer (21), angle (23), and
4 Position seat assembly on existing support spacers (18, 19, 20, 22). Drill remaining rivet
fit~ngs and secure using pins (1). holes as required.
i. Attach seat assembly to floor supports with Install channel assembly (15) using rivets
locking pin (3). (13~ 14, 16). Remove clecos as required.
J. Clean all drill chips and foreign material m. Install spacers (20) using rivets (5, 6, 7).
fromwork area, particularly the tops of fuel cells. Remove clecos as required.
4 Remove temporary backing; close access Install angle (23) and spacer (21) using
panels. rivets (5, 8). Remove clecos as required.
3-16. INSTALLATION OF VERTICAL SUPPORT. o. Install spacers (18, 19, and 23) using rivets
(8,14). Remove clecos as required.
3-17. The vertical
support installation consists
of two the necessary doublers, spacers,
supports, p. Position doubler (12); mark and drill attach-
and attaching hardware for installation. The two ment holes as required.
supports are mounted to the aft side of canted
bulkhead 78. 50 and are used to support the four q. Install doubler using rivets (9, 10).
arm assemblies for the litters. Accomplish these
operations in order to permit installation of the r. Position cover (26); mark and drill attach-
vertical supports: ment holes as required.
a. Identify all components and attaching hard- s. Install cover using rivet (24).
ware for the vertical support installation.
t. Position cover (25); mark and drill attach-
b.
Verify removal of all necessary equipment, ment holes as required.
components, and attaching hardware from heli-
copter to provide access to work area, u. Install cover using rivets (24).
3-4
0,00
~---------------20.
1
t ,40 ,25 21F3~ t
2,30
i1 DOUBLER
,14
,25TYP
t 25
,25
1_
1
,50 19.740
BELT AS~EMBLY I II BELT ASSEMELY

2EQ SP
4,490
f
DOUBLER LOCATION 25
a~olo
5
,490
PILE TAPE
I +I T 2EQ SP
,30
(369D290223-9) /c2 PL 19~7Po
~L.25
,56 R II PL 25
1
1,60 (CUT OUT) TYP
c1.00 1
PILE TAPE 2,30

(369~290223-73
;2,00 t..
i mL
,111 ,45
,90
,56 R 4 PL ,26~
5,~0; 1 I It) M (CUT OUT)
8,50 STA
PILE TAPE ML
113,85
(369D290223-5)
WL
33,00
t O SUPPORT LOCATION
,50
WL VIEW LOOKING AFT

35.0
WL
32,00
1. STA,124,00
,30
VIEW LOOKING OUTBD

LH SIDE
O 211E TAPE LOCATION
STA
124,00
47-982
Figure 3-2. Attendant seat installation
3-5
BL BL
17,00 11,30
LH ,88 TYP, LH
II PLACES
DOUBLER
NOTE 1
I I/I
VERTICAL SUPPORT
NOTE:
1,ADD NEW RIVETS
mi
SPACER
NOTE 1 SPACER
NOTE 1
B
ANGLE
TRACE WL 21,50 hcA
ON CANTED STATION
c
++i++llCII"+
4
NOTE 1
B d~ A
NOTE 1 BL CHANNEL
17,00 EXISTING 11,30 ASSEMBLY
LH RIVETS LH
BL BL
6,00 5,76
BC BC LH LH
13,3115 12,875
LH LH
TRIM EDGE OF
-4 369D29O179
TRIM EDGE OF
9TIFFENEfi 369D290178 IIII /SPACER
AS SHOWN ---r\i SPRCER AS SHOWN
-r I
369D29O174
.25
EXISTING EDGE ANGLE
EDGE
OF STIFFENER
OF STIF ENEREXISTING
WL 21,50 WL 21,50
3691)290181-1 ~H 369B290181-1
3690290181-2 RH~ 2-183092D63HLRH~
41-981-1
Figure 3-3. Structure modification for vertical support installation (sheet 1 of 2)

3-6
BL BL BL
369A2516-65
6,00 10,00 17,00
(REF)
LH LH LH
369H2508-81
369D290173
(REF)
COVER D
i
t +14~!+!1
I ~tlt
1,25
+:__i_"""
Ic
1;25
,13R
TYPICAL CUTOUT
369A2516-179 Ct2,
(REF)
\C~2,0d
369D290182
DOUBLER
EL BL
BL
17,00 10,00 6,00
RH RH
369D290172
,13R
COVER
D
~U r:
fi~ic Ic I+
2,12\ CUTOUT JZ.ZS

~r/ It i D
It-i I+~ I~
3,04~1 D0UBLER
REMOVE 369A2316-65 CHANNEL

AND TRIM FOR CLEARANCE TC
INSTALL 369D290182 DOUBLER
CANTED STATION
O
47-981-2
Figure 3-3. Structure modification for vertical support installation (sheet 2 of 2)
3-7
v. Position supports (3) and secure in place (2) Place neoprene shim under door seal
using bolts (1) and washers (2). Secure bolts with as required to accomplish water-tight capability.
lockwire.
3-21. Helicopters equipped with the older door
3-18. BUBBLE DOORS. bolting system require rework of the
rear door
frames to accommodate the bubble hook latching
3-19. The rear doors installation consists of two striker. (Refer to figure 3-6 for rework
litter high doors with upper and lower right and procedure.
left hand hinge assemblies, two bubble and door
adapter assemblies, prop assembly, covers, and 3-22. _R_ELACEMENT OF HELICOPTER
necessary attaching hardware. EQUIPMENT.
3-23. Replace helicopter equipment removed to

CAUTION
permit litter kit installation. (Refer to HMI
Vol i.
Do not attempt to install bubble doors with
hook latching-type strikers on helicopters 3-24. WEIGHT AND BALANCE.
with serial numbers earlier than 0795. Doors
will be damaged beyond repair. Refer to 2-25. Weight and balance changes resulting from
paragraph 3-21. installation of the litter kit are listed in table 3-2.
After installation of litter kit, incorporate changes
9-20. To install when hook latching-type striker
in helicopter weight and balance records as in-
is on the door frame:
structed in HMI Vol 2.
a. Hang door as a unit, using masking tape or
equivalent to secure door and matching striker
plates on fuselage with latches (18, fig. 1-2) on Table 3-2. Weight and balance data"
doors. (Refer to figure 3-4.)
Longitudinal Horizontal
b. Trim door skin (both doors) to match fuse-
Weight Arm Moment
lage cutout.
(Ib) tin.) (in.-lb/100)
c. Locate and drillhinges. Rivet hinges to
door assemblies. In use load condition
d. Cut out
a rectangular hole in door frame Added 117. 7 97.4 114. 6
(both doors) and trim to ensure snug fit of the
369D290245-3 land -4) cover to the door frame. Removed 0 0 0
Install cover with sealant (table 3-1, item 4).
Changed +117.7 97.4 +114.6
Install fuselage mount for gas spring (door
prop) mount. (Refer to figure 3-5.) Stowed condition
f. Install gas spring mount on door. Added 117. 7 107. 2 126. 2
g. Install gas spring betweendoor and fuselage. Removed 0 0 0
h. Rig door latch mechanisms: Changed +117. 7 107. 2 +126. 2
(1) Shim latch blocks and adjust strikers *SN-0940 and subsequent: door assembly becomes
inboard and outboard to achieve proper hook standard; subtract 22 Ib at Sta 82. 7 aft passenger
latch/striker engagement. doors (door prop assembly included).
3-8
STA
97,93
369H92702-71 DOOR STRUCTURE (SHOWN)

369H92702-72 DOOR STRUCTURE (OPPOSITE)
,198
(NO, 8) DIA 2 HOLES
,2011
BOLT 2 PLACES
WASHER 6 PLACES
SPACER 2 PLACES
NUT 2 PLACES
II
I
is
369H92747-1 HINGE (SHOWN) 369H20118-23

369H92747-2 HINGE (OPPOSITE) LATCHING SYSTEM (SHOWN)
369H2048-24
o?
LATCHING SYSTEM (OPPDSITE)
I
P;
RIVET
2 REQ, FLUSH
Il
OPPOSITE SIDE
I: ii
II
369D22010 DOOR LOCK
/I
II (SHOWN) AND (OPP.) REF
RIVEI
8 REQ~ II 369022011 SPACER
/I// (SHOWN) AND (OPP.) REF
/I
1,60
i
RE13,///
RIVET
4
STA
113,18
18~
3690290151-501 BUBBLE AND

1111 DOOR ADAPTER ASSY (SHOWN)
3690290151-503 BUBBLE AND
DOOR ADAPTER ASSY (OPPOSITE)
369H92034-1 HINGE (SHOWN)

369H92034-2 HINGE (OPPOSITE)
BOLT
WASHER
STA 15 PLACES EACH
n
78,22
STA
STA 93,25 112,84
47-1026
Figure 3-4. Litter high door installation
3-9
Section 3 Opt Eqpt ~Manual CSP-OI1
GAS SPRING ASSY

RIVET
7 REQD
(PICK UP EXISTING RIVET
PATTERN ON BOTTOM ROW)
~,2(j
36902902115-3 COVER SHOWN

1 REGID
A 369D290245-~ COVER OPP
,30 1 REQD
TYP
,97
TYP I
+I I+
t t,35
f 5 If t-
2,20
WL
13,10 13,10
369D290231-3 BRACKET ASSY, 1 REQD

A
3690290230-1 DOOR PROP SUB ASSY-L,H, DOOR SHOWN
3690290230-2 DOOR PROP SUB ASSY-R,H, DOOR OPP
VIEW LOOKING OUTBOARD
GAS SPRING (REF)

WASHER, 2 REOD
NUT, 1 REQD
SECTION A-A
47-1016-1
Figure 9-5. Door prop (sheet 1 of 2)
3-10
3690290231-13 DOUBIE~ ~C
369D290231-9 STIFFENER SHOWN 1 REOD
369D29O231-10 STIFFENER OPP 1 REOD
t~ C II+
r ~l-------irl I /STA
RIVET 8 REQ 81,27
WASHER, 2 REQD -I 1
NUTI 1 REQD
otlPatl
b: GAS SPRING ASSY
369D290231-11 CLIP, 1 REQD

369D29O231-12 CLIP, 1 REQD
i.._ C1
SECTION CC
RIVETS, 3 PLACES
tl~L ,40
f
,50
1,00
SECTION B-B
369A25O8-83
VIEW LOOKING DOWN

~lolll I I LEFT HAND SHOWN
RIGHT HAND OPP
II D-D
SECTION
,10
.10
369D29023-9 STIFFENER
r,40 FLO~R SKIN
RIVETS, 3
1,00
117-1016-2
Figure 3-5. Door prop (sheet 2 of 2)
3-11
369H3O14-EO3 DOUBLER, 1 REQUIAED

MATERIAL 2024 T3 AL ALY SH,
PER gq A 250/4
DOOR STRIKER
2,10 LG X ,032 THK X ,45 WD
LOCATION N0,4
DOOR STRIKER FINISH WITH ZINC CHROMATE PRIMER
LOCATION N0.3
DOORSTRIKER
.218
~OCATIDN N0,2 ,229
DLA, 2 HOLES
2 EQ.
r SPACES
,20
000R STRIKEA
A TION NO.1 ,15X
MS20604AD3W2 BLIND RIVET
.15 X 1150 CHAMFER
3 REQUIRED EA (IN LATCH LOCATIONS
II PLACES
NO. i, 2, 3 AND 4) OR EQUIVALENT
AN96OPD1O WASHER
OR
HS306-322H WASHER
DRILL .254
DIA HOLE 2 PLACES 2 RE~UIRED
tfD ICAL FOR ALL BUSHI EACH STRIKER
2 HOLES IN LINE
62980-1 AND 2 1_ II E~S206011AD3W2

62984-1 AND 2 BLIND RIVET
DOORSTRIKER\ \~tu 3REQD,
(SEE NOTE 1)
rl"
369H3014-E03 DOUBLER
NAS119OE3P30 PAN HEAD SCREW 1 REQUIRED
1 REIIUIRED EACH STRIKER (SEE NOTE 2)
369H3014-EO5 BUSHING
8 REQD, PER DOOR FRAME
NAS1189E3P30 FLUSH HEAD SCREW (SEE NOTE 3 AND 4)
1 REQUIRED EACH STRIKER
O AN960PD10 WASHER
(SEE NOTE 6)
NOTE:
1, LOCATION NO, 1, 2, 3,4, AS AN ALTERNATE

369H2401-83 SH
METHOD TO RIVETING, -j DOUBLER MAY BE
(SEE NOTE 5)
BONDED TO DOOR FRAME.
2, MAKE FROM 2024-T3 AL. ALLOY SHEET PFR
8g-A-250/4, 2.10 LG, X ,032 THK, X .45 ~D,
FINISH WITH ZINC CHROMATE PRIMER,
q
MS21O42L3 OA
3, MAKE FROM 0,25 OD X 0,028 WALL TUBING,
304 CRES STEEL 1/8 HARD PER PiII. T-6845, MS21042-3 NUT
SEAMLESS, TYPE 1, I,D, TO BE REAMED TO 2 REQD, EACH
STRIKER
0,190
0,194 (ALTERNATE MATERIAL: 0,25 OD, X
0,028 WALL TUBING. 304 CRES STEEL 1/8
HARD PER MIL, T-68115, SEAMLESS TYPE I)
LENGTH =1,30. FINISH WITH ZINC
5, SHIM ALL STRIKERS USING 369H2401-83
SHIM AS REQUIRED TO MAXIMUM SHIM THICK-
O BOND BUSHINGS INTO PLACE
USING EC1838 SCOTCHWELD
PRIMER.
NESS OF 0.20 FOR LATCH LOCATIONS ND.
4, DRILL ,254 DIA. HOLES IH DOOR FRAMF OI~I 1 THRU 4,
,258
SAME AS NAS1329CO6-75 RIYNUTS DRILLED 6 AN96OPD1O OR HS306-322H WASHER ~AY BE
OUT TO PERMIT BUSHING INSTALLATION. USED WITH NUT AS ALTERNATE TO 369H3014-
INSTALL BUSHING. BOND INTO PLACE WITH EO3 DOUBLER AT ND. 410CATION ONLY, TRIM
Ecles SCOTCHWELD. TRIM BOTH FACES OF WASHER AS REOUIRED TO ACCOMMODATE SUR-
ROUNDING STRUCTURE, REMOVE ANY INTERFERING
BUSHING FLUSH TO f,000 OF SURFACE.
,010 RIVETS, 47-1020
Figure 3-6, Door frame rework procedure
3-12
CSP
084

arad
Maintenance
FOR
TDR-950 TRANSPONDER SYSTEM
USED ON HUGHES HELICOPTERS
500D (MODEL 369D), 500E (MODEL 3693), 530F (MODEL 369F)
AND 530F PLUS (MODEL 369FF)

PREV1OUS ISSUES OF THIS PUBLICATION
COD011085 Issued 30 September 1980

Reissued 01 November 1985
NI FG,
INTRO
INSEIT U1EfT CHANGED PAGES, DLSTI~OY SUPEISEDED PAGES.

IIST OF EFFECTIVE PACES IHE PSTERISK INDICAIES PAGES CHANGED. ADDED. OR DELETED BY THE CURREHT CHANGE.
Page Issue
Title.......... 01 Nov 1985

A thru B........ 01 Nov 1985
CBlank........ 01 Nov 1985
i............. 01 Nov 1985
ii Blank 01 Nov 1985
F-l........... 01 Nov 1985
F-2 Blank.....,. 01 Nov 1985
1-1 thru 1-7..... 01 Nov 1985
1-8 Blank 01 Nov 1985
2-1 thru 2-11..... 01 Nov 1985
2-12 Blank 01 Nov 1985
CSe-084 Opt Eqpt Manual
MDHC HELICOPTERS TECHNICAL MANUAL RECOMMENDED CHANGE REPORT
revisions.
McDonnell Douglas Helicopter Company


6/A141
Originator
Address
Figure Number(s)
Rem arks /Recomm endations
B/C
RECOa6) OF REVISIONS
CSP-084
MFG REV
CSP-084 Reissue 11/1/85 2/27/86 ATP/KK


REV NO
Section Page
FOREWORD F-1
Purpose an4 Content of

this Manual F-l
F-3. Applicability.... F-l

Combined Optional
Equipment F-l
F-7. Organization of Contents.. F-l
F-9. Use of this Manual.... F-l
F-lr. Related Publications F-I
Revisions........... F-l
1 ILLUSTRATED PARTS LIST..... I-1

1-3. Detailed Parts List...... I-1
Section Page
2-1. Generalrnformation 2-1

2-11. Controls andlndicators 2-1
2-~3. Transponder Unit
Lighting. 2-4
2-15. Power Conversion Kit 2-4
2-17. Operation. 2-4
2-19. Operational Check. 2-4
2-20. Self-Test 2-4
2-22. Ramp Test............ 2-4
2-24. Troubleshooting ........2-7
2-26. Inspection ............2-7
2-28. Repair. 2-7
2-32. Removal/Installation 2-7
2-33. Component Removai....:.. 2-7
2-35. Component Installation 2-10
2-36. Wiring and Schematic
Diagram 2-11
i/ii
F-l. PURPOSE AND CONTENT OF THIS F-7. ORGANIZATION OF CONTENTS.
MANUAL.
F-8. The contents of this manual are grouped
into sections and sub-sections as outlined in the
F-2. This manual supplements information con- Table of Contents.
tained in the Handbook of Maintenance Instruction
(HMI) Vol 1, and 369D and 369E/F Illustrated
Parts Catalog OPC), and contains instructions for F-10. This manual is for use by operators of
maintenance of the TDR-950 Transponder and Hughes helicopters equipped with the Collins
associated components. TDR-950 Transponder. Although this manual is
a separate publication, it should be kept with
HMI- Vol I, HMI Vol 2, 369D and 369E/F

F-3. APPLICABILITY.
IPC and other handbooks listed in HM1: Vol I,
Section 1, that form the primary information file
F-4. TheTransponder system is applicable for for the helicopter.
use on any Hughes 500D (Mode1369D), 500E
(Model 3693), 530F (Model 369F) and 530F Plus
(Model 369FF) helicopter. F-12. Reference is made to HMI Vol 1, 369D
and 369E/F IPC, the CSP supplement to basic
handbook, and the Collins Transponder manual as
F-5. COMPATIBILITY OF COMBLNED
required to accomplish instructions contained
OPTIONAL EQUIPMENT. herein.

F-6. For compatibility information on which
optional equipment may or may not be used in F-14. Changes and revisions to contents of this
combination at the same time, refer to Section 21 manual are made as defined in HMI Vol 1,
of the HMI Vol 1. Section 1.
F-1/F-2
1-1. SCOPE AND CONTENTS. in this parts list because of engineering require-
ments. No "installation drawing" exists. A
"REF" in the quantity column indicates the item
1-2. This illustrated parts list provides, by
is required by engineering configuration, in
means of text (parts list) and companion illustra-
another publication, but is identified in this man-
tions, complete parts requirement for installa-
a
ualfor system continuity. Items listed, however,
tion of the TDR-950TranSponder, provided by
represent a complete parts definition of compo-
McDonnell Douglas Helicopter Company, Culver
nentsrequired to maintain the TDR-950 Trans-
City, California.
ponder system.
1-3. DETAILED PARTS LIST.
1-5. ILLUSTRAT~ONS.
1-4. The detail parts list furnishes information

1-6. Isometric. illustrations are provided for the
for procuring replacement parts for the TDR-950
detailed parts list. The illustration is exploded
Transponder system. A normal "Installation
to the extent necessary to show parts relationship
drawing-assembly drawing-component" column
indenture relationship cannot be fully adhered to
for the Transponder system.
1-1
Section 1 Opt Eqpt Manual CSP1084
91
C~S
O
47 -1000-1A
Figure 1-1. TDR-950 Transponder system, early configuration (sheet 1 of 2)
1-2
CSP-084 Opt Eqt Manual Section 1
2 d
22 \//,9
19 18
21
20
1 5
23
21 4
47-1000-3
Figure 1-1. TDR-950 Transponder system, early configuration (sheet 2 of 2)
1-3
FIG. UNITS USABLE

NO. NO. ASSY CODE
1-1- TDR-950 TRANSPONDER SYSTEM

-1 SCREW, LOCKING (Component of Transponder) REF
-2 622-2092-001 TRANSPONDER (Component of 423-021). REF
(See Collins Manual 523-0766464 for bkdn)
-3 "340-0012-000 RING, RETAINING. 1
-4 *628-5359-001 WASHER, SHIM 1
-5 423-072-711 CABLE ASSY, COAXIAL. REF
(Component of 423-071)
-6 357-7532-010 CONNECTOR (P48) REF
-7 KC59-218 I.. CONNECTOR (P49) REF
-8 423-072-713 1 CABLE ASSY, COAXIAL. REF
-9 KC39-51 1.. CONNECTOR (549) REF
-10 KC59-270 I.. CONNECTOR (P50) REF
-11 *628-6095-001 WASHER, IDENT. 1
-12 *013-1572-010 1 ANTENNA I 1
-13 *330-1779-040 SCREW, 4-40x 1/4 2
-14 *343-0136-000 SCREW, 4-40x 7/16 2
-15 423-026 WIRE HARNESS ASSY, TDR-950 XPDR....... REF
-16 372-7513-080 CONNECTOR, BLOCK (P47)............. REF
-17 628-5673-001 1 CONVERSION MT. 1
MS3367-1-9 I TIE STRAP AR
-18 *343-0134-000 1 SCREW, 4-40x 5/16 PPH................ 1
-19 *310-0045-000 1 WASHER, FLATNO. 4.................. 1
-20 "150-1540-000 CLAMP, CABLE 1
21 *333-0605-000 1 LOCKNUT, 4-40 3
-22 *310-0046-000 1 WASHER, FLATNO. 6...........,....., 2
-23 "628-8105-004 1 PIN, GUIDE 2
-24 MS24693S26 SCREW (Component of 423-021) 4
-25 AN960PD6L I WASHER (Componentof 423-021) 2
-26 MS21042L06 NUT (Componentof 423-021) 2
-27 *628-5612-001 1 TRAY, MOUNTING 1
-28 429-4424-31 TERMINAL BOARD ASSY (TB300) REF
-29 429-4424-51 TERMINAL BOARD ASSY (TB502) REF
*Component of Transponder Kit. Required in Collins TDR-950

Transponder Manual 523-0766464,
1-4
i9i:i(
i.~ii(l
~Q
O
O
Figure 1-2. TDR-950 Transponder system, current configuration (sheet 1 of 2)
1-5
Section 1 Opt Eqpt Manual C6P-084
~19
-iI d6
1 9
12
s~
O
a
O
47-1000-4
Figure 1-2. TDR-950 Transponder system, current configuration (sheet i of 2)

1-6
FIG. UNITS USABLE

NO. NO. ASSY CODE
1-2- TDR-950 TRANSPONDER SYSTEM

*628-5612-001 INSTALLATION KIT 1
ii 622-2092-001 1 TRANSPONDER I 1
-2 *013-1572-010 1 ANTENNA 1
-3 *628-6095-001 IDENT. 1
WASHER,
-4 *KC-59-101 COAXIAL, PLUG(P954) 1
-5 *369D24166-11 1 COAXIAL CABLE ASSY.. 1
1
-6 1 *357-7532-030 COAXIAL, PLUG (P952).....
*628-5612-001 1
-7 TRAY, MOUNTING
-8 628-8108-001 1 POWER CONVERSION KIT 1
4
-9 3333-0605-000 LOCKNUT, 4-40............
4
-10 *310-0046-000 WASHER, FLAT NO. 6........
-11 *628-8105-004 2
PIN, GUIDE
-12 *330-1779-040 1 SCREW 4-40 x 1/4 2
-13 *372-7513-080 CONNECTOR, BLOCK (P951)............ 1

-14 *MS3367-5 AR
STRAP, TIE...............
-15 2TC13-3 I CIRCUIT BREAKER (CB202) 1
*340-0012-000 1
-16 RING, RETAINING..........
-17 *628-5359-001 1
WASHER, SHIM
*Component of Transponder Kit, Refer to Collins TDR-950

Transponder Manual 523-0766464.
1-7/1-8
CSP-084
2-1. GENERAL INFORMATION. dropping resistors (referred to as "Power Con-

version Kit" in this manual) mounted on a bracket
2-2. SCOPE. attached to the back of the transponder mounting
tray (see figure 2-2).
2-3. This section contains maintenance informa-
tion for use by maintenance personnel responsible 2-10. Two series connected RG-223/U coaxial
cables connect transponder to a vertical antenna
for organizational (field) maintenance of the TDR-
950 Transponder
and related components. The mounted at the forward underside of the helicopter
information and specific instructions include (see figures 1-1 and 2-3).
description, operation, operational check,
troubleshooting, inspection, repair, and removal/ 2-11. CONTROLS ANDINDICATORS.
installation procedures.
2-12. Controls and indicators for operating the
2-4. REFERENCE DATA. TDR-950 Transponder are all located on the
transponder front panel. The controls are identi-
2-5. Information on helicopter components that fled infigure 2-1, and functionally explained in
interface with the Transponder installation is table 2-1 and the sub-paragraphs that follow.
contained in HMI Vol 1 and the 369D IPC.
For information applicable to specific associated a. OFF-SBY-ON-ALT-TST Function Se_lector.
optional equipment, refer to the CSP supplement Th~ funFtionselector controls application
to basic handbook. Although pertaining to higher primary power to the transponder and also con-
than organizational level maintenance, reference trols transponder mode of operation. A 20-
will be made in this section to Collins TDR-950 second delay occurs from the time primary power
Transponder Instruction Manual 523-0766464. is applied until operation of the transponder is
obtained. The 20-second delay allows the trans-
2.-6. DESCRIPTION. mitter tube in the transponder to warm up and
stabilize. Setting the function selector to the
2-7. GENERAL. ON or ALT position enables the transponder.
Reception of a valid interrogation in either of
2-8. The TDR-950 Transponder mounted on the these two modes initiates generation of faulty
helicopter instrument panel provides identification pulses. For this installation, the ALT position
of the helicopter to interrogating aircraft or of the function selector is not used. With the
ground stations. Interrogated by coded radar function selector to ON, the configuration of the
pulses transmitted by an aircraft or ground sta- reply pulse train is determined by the setting of
tion, the TDR-950 Transponder automatically the front panel code selector switches and the
replies with a series of coded pulses when an mode of the interrogating signal. With the
interrogation is determined to be valid. A function selector set to SBY position, application
special position identification pulse (SPIP) is also of power to the transponder is maintained and
available. This special pulse is added by the pilot response to any interrogation is inhibited. The
upon verbal request of the interrogator. SBY position is normally selected during taxiing
operations. Setting the function selector to the
TST position enables an operational self-test of
2-9. The TDR-950 Transponder reply frequency the transponder. The self-test is a confidence
is 1090 rt3 MHz. Peak power output of the test and provides a valid indication of the trans-
transponder is 250 watts ~1 dB at a duty cycle of ponder operating condition. The TST position is
1G/o Or less. The Transponder is energized at a spring loaded; therefore the function selector
14 volt level. The voltage is obtained from a shall be held in place to accomplish the test.
12-ohm, 30 watt voltage dropping resistor con-

nected through a circuit breaker on the circuit b. REPLY Lamp. The reply lamp illuminates
breaker panel to the helicopter 28 volt bus (see wh~enever (1) a response is made to a valid in-
figure 2-4). The resistor is one of two voltdge terrogation, (2) the transponder IDENT button is
2-1
CODE SELECTOR
FUNCTION SWITCH_ES
SELECTOR
ON/i
OFFSBY ALT~o \o
REPLY~ 6"" Collins fronsponder

O
TDR-95O TSO
REPLY LAMP
IDENT BUTTON
LAMP DIMMER
117-851
Figure 2-1. TDR-950 Transponder, controls and indicators
Table 2-1. Controls and indicators functions
Control or Indicator Function
Function selector Selects transponder mode of operation: unit off, standby, on,
altitude, or test.
REPLY lamp Lamp flashes each time a response is made to a valid interrogation.
The REPLY lamp will remain on for approximately 20 seconds after
releasing IDENT button; this signifies transmission of the special
position identification pulse (SPIP). Selection of TST position lights
the REPLY lamp if the transponder is operational.
IDENT button Momentarily pressing IDENT button adds a SPIP to the normal reply
pulses for helicopter identification.
Lamp dimmer Rotation of IDENT button sets brightness of the REPLY lamp.
Code selector switches Establish the mode A identification reply code.
2-2
CONNECTOR BLOCK P47 (EARLY CONFIGURATION)

P51 (CURRENT CONFIGURATION)
*14V INPUT WIRE FROM CB109 (EARLY

CONFIGURATION)
sGROUND WIRE IPIN 1)
CB202(CURRENT CONFIGURATION) THROUGH TB300-2
AND CONVERSION~KIT (PIN 14)
+CONVERSION KIT
GUIDE PIN
o
ic: :>i
GUIDE PIN
ANTENNA CABLE CONNECTOR
FROM LIGHT DIMMER THROUGH
P48 (EARLY CONFIGURATION)
CONNECTOR P52 (CURR~IT CONFIGURATION) TB502 AND CONVERSION KIT (PIN 15)
ANTFNNA COAXIAL CABLE

47-1001A
COMPONENT OF 423-026 WIRE HARNESS ASSEMBLY
Transponder mounting tray rear view
Figure 2-2.
NUT
LOCK
WASHER
IDENT
WASHER
GASKETSEALING
8 47-1002A
Figure 2-3. Antenna installation
2-3
pressed, or (3) the TST function selector position 2-19. OPERATIONAL CHECK.
is selected.
2-20. SELF-TEST.
NOTE
2-21. The following is a preliminary test to
When response is made to an interrogation,
a determine operational readiness.
the reply lamp will flash on and off. Press-
ing the IDENT button or selection of the TST a. On circuit breaker panel, close XPDR
position lights the relay lamp continuously, circuit breaker (push in).
c. IDENT Button.Pressing the IDENT button b. Set transponder OFF-SBY-ON-ALT-TST

ad~js special position identification pulse (SPIP)
a function selector switch to ON.
to the normal reply pulses. This provides an
identification display at the interrogating source. NOTE
d.
Lamp Dimmer. Dimming of the reply lamp Upon setting function selector to ON, a 20-
is accomplished by turning the IDENT button. second delay occurs before transponder
This allows pilot to maintain an optimum reply becomes operative.
lamp brightness for any ambient lighting condition.
c. Rotate and hold function selector to TST
e. Code Selector Switches. The reply code is (test) position.
selector switches.
The 4-digit code selected determines the con- NOTE
figuration of the reply pulse train. The reply
code is displayed in the code windows. Setting function selector to the TST position
shall cause the REPLY
lamp to illuminate,
2-13. TRANSPONDER UNIT LIGHTING. signifying that the transponder is operating
properly. The REPLY lamp shall remain
2-14. Transponder indicators are illuminated by on as long as the function selector is held to
three TI 3/4, 14V lamps internally mounted on the TST position.
the transponder circuit board. The transponder
lamps are lighted by pressing the INST PNL cir- d. Release XPDR circuit breaker when test is
cult breaker CB104 on the circuit breaker panel, concluded.
Brightness is controlled by the OFF-BRT dimmer
knob on the edgelighted switch panel. 2-22. RAMP TEST.
2-15. POWER CONVERSION KIT. 2 -23. The followi~g operational/p e rfo rm an ce

tests should be made after transponder mainte-
2-16, A 28 to 14 volt power conversion attach-
ment is mounted on the rear of transponder
nance or replacement. The instructions will
include tests for (1) transmit power, (2) transmit
mounting tray. This kit consists of a 56-ohm,
15 watt resistor which code, (3) reply radio frequency, (4) receiver
provides power for illumi-
nation of the sensitivity, and (5) side lobe suppression.
transponder unit. 28 to 14 vdc is
provided by the power adaptor mounted on the
back of the instrument panel, a. Description of Test Equipment.
2-17. OPERATION. (1) IFR Model ATC-GOOA Transponder/

DME Ramp Test Set with Test Antenna.
2-18. To ready the TDR-950 Transponder for
operation, proceed as follows: (2) 34 dB Attenuator Pad at 1090 MHz.
a. Prior to flight, perform self-test operation (3) Bird Electronic Corporation Mode14314
(pala 2-20). After ensuring transponder is oper- Thruline R. F. Directional Peak Wattmeter.
ational, reset function switch selector to SBY

position. (4) Bird Electronic Corporation Model 5005
High-Power Element.
b. Set code selector switches to desired
reply
purse train configuration, b. Initial Conditions.
c. When airborne, set function selector switch

(1) Tests are to be performed in an open
to ON.
area.
2-4
(2) Connect the 34 dB pad to the OUTPUT (8) Ensure BATT-OFF-EXT switch on heli-
Connector of the ATC-GOOA Test Set. copter switch panel is set to OFF.
(3) Disconnect coaxial cable (8, fig. 1-1) (9) Connect a regulated 28V de auxiliary
from transponder antenna (12) under copilots power unit to helicopter external receptacle 5100.
floor and connect a coaxial cable direct from the
34 dB pad to disconnected antenna cable (8). (r0) Set BATT-OFF-EXT switch to EXT.
(4) Initially set the ATC-GOOA controls as (11) On circuit breaker panel, press XPDR
follows: circuit breaker (CB 109).
Control setting (12) Set the

transponder function selector
switch to SBY tallow
20 seconds warm-up). Verify
Frequency/Power Switch Power that the transponder panel lights are on and con-
Transmitter Frequency 0 trollable by the dimmer control.
Frequency/Gain Control CCW
Mode Switch A/C Code c. Transmit Power Test.
Transponder Signal Control CCW
Framing Control 0 (1) Set the transponder function selector
Interspacing 0 switch to ON. The REPLY lamp shall be ON.
Power Switch Off
(2)
Take the power reading on the ATC-
(5)
Set the ATC-GOOA POWER SWlTCH to 600A Frequency/Power Meter. The power shall
BATTERY. be a minimum of 148 watts with the ATC-GOOA
connected to the 34 dB pad.
NOTE
NOTE
The battery power to the ATC-GOOA is turned
on by momentarily pressing the POWER Power readings depend on length and type of
SWITCH downward once. The battery power cable.
is applied through a seven to ten minute
timer. To turn off battery power before (3) Turn the ATC-GOOA power OFF. Place
timer runs out, press the switch a second the transponder function selector switch to SBY.
time. When the BATTERY TEST SWITCH
is pressed, the TRANSPONDER RELAY/ (4) Disconnect the 34 dB pad and coaxial
DNIE PRF METER is used to monitor the cable test equipment and reconnect helicopter
battery voltage. The left edge of the white antenna cable (8, fig. 1-1) to antenna t12). Con-
band indicates 12. 1V or a discharge condi- nect the test antenna to the ATC-GOOA.
tion. A fully charged batterywill indicate
well inside the band. If the battery voltage (5) Initially, place the test antenna three
is below 12. 1V, the battery
timer will imme- feet from the helicopter antenna.
diately switch the set off.
(6) Turn the ATC-GOOA power ON. Place
(6)
Set the SYSTEM and LAhiP TEST transponder function selector switch to ON.
SWITCH in the UP position. The readout on the
Test Set must read 0042. Set the MODE SELEC- (7) Take a power reading on the ATG-GOOA
TOR SWITCH to the A/C ALT position. Set the Frequency/Power Meter. If the power reading is
SYSTEM and LAMP TEST SWITGH in the UP not the same as noted at step (2) above, move the
position. The readout on the Test Set must read test antenna closer or farther from helicopter
126. 7. If these readouts do not appear, there is antenna until power reading is the same.
a malfunction in.the ATC-GOOA. Setting the SYS-
TEM and LAMP TEST SWITCH in the DOWN NOTE
position will turn on all indicator lamps on the
front
panel of the ATC-GOOA. Return the MODE Do not place antennas closer than 15 inches
SELECTOR SWITCH to the A/C code. to each other.
(7) Initially set the TDR-950 Transponder

controls as follows: (8) Set transponder function selector switch
to SBY.
Control Setting
Function Selector OFF (9) Disconnect transponder cable from
Code Selector Knots i, 2, 3, 4 antenna under copilots floor. Connect the
2-5
r.f. wattmeter between transponder and antenna (2) Set the ATC-GOOA Transponder Signal
using a 18 inch maximum coaxial test lead. Control fully CCW. The Transponder Replay
Meter shall indicate 100 percent.
(10)
Install the 5005 High Power Element in
the wattmeter with arrow pointed toward antenna. (3) Adjust the Transponder Signal Control
CW until the Transponder Reply Meter reads 90
(11) Set the transponder function selector percent (the needle will continually fluctuate;
switch to ON and record the wattmeter forward take an average reading). The Transponder Sig-
power indication. nal Control shall indicate -73 ~4 DBM.
(12) Set the transponder function selector (4) Set transponder function selector
switch to SBY and reverse the wattmeter element switch to ALT.
to point toward transponder.
(5) Set the ATC-GOOA Selector Switch to

(13) Set function selecior switch to ON and A/C ALT (Mode C) and repeat steps (2) and (3)
record the wattmeter reflected power indication. above. The NO LAMP will light and there will
be no readout.
(14) VSWR chart or a nomograph,
Using a
determine the VSWR. The resulting VSWR ratio (6)
The Transponder Signal Level Control
shall not exceed 1. 2 to 1.0. reading shall not be greater than +1 DB different
than the reading of step (3) above.
(15) Set function selector switch to SBY.
(7)
Set the Transponder Signal Level
(16) Disconnect the r.f. wattmeter and test Control to fully CCW and set the Mode Selector
lead. Reconnect transponder antenna cable to Switch to A/C code.
helicopter antenna.
(8) Set transponder function selector
d. Transmit Code Test. switch to ON.
(1) Set function selector switch to ON. g. Side Lobe Suppression Test.
(2) Select three or four different codes (1) Set the Transponder Code Selector
on the transponder and verify that the same num- switches to~any code other than 0000, 7600, 7700,
ber is shown on the ATC-GOOA readbut and that and 7777.
the REPLY light is ON.
(2) With the Transponder Signal Control
full CCW, the Transponder Replay Meter shallin-
yz~
CAUTION dicate 100 percent. Adjust the Transponder Sig-
nal Control CW until the meter indicates 90 per-
cent (the needle will continually fluctuate; take an
Do not use codes 0000, 7600, 7700, or 7777
during tests, average reading). Note indication on the Trans-
ponder Signal Control and adjust the control 3 dB
less than this reading. The Transponder Reply
e. Reply Radio Frequency.
Meter should show 100 percent at this setting.
(1) Set the transponder code selector NOTE

switches to any code other than 0000, 7600, 7700,
and 7777. If the transponder sensitivity is near the in-
sensitive limit, it may be necessary to move
(2) Set the ATC-GOOA Frequency/Power the ATC-GOOA test antenna closer to heli-
swi~ch to FREQUENCY and adjust the Frequency copter antenna to obtain proper indications.
Gain Control for a midscale reading on the Do not allow antennas closer together than 15
Frequehc-y/Po~er Meter. inches. If test antenna is moved, repeat
step (2) above.
(3) Adjust the Frequency Control for a
peak indication on the Frequency/Power Meter. (3) Set the SLS switch to 0 dB (P2 pulse
The Frequency Control shall indicate a maximum equals Plpulse). The transponder shall stop
of ~t3MHz. all replies.
t. Receiver Selrsitivity Test.

(4) Set the SLS switch to -9 dB (P2
(1)
Set the transponder CODE SELECTOR pulse is 9 dB less than Pi). The transponder
SWITCHES to any code other than 0000, 7600, shallreply at least 90 percent (minimum) to
7700, and 7777. 100 percent.
2-6
(5) Set Transponder Signal Control to fully repair should be accomplished by personnel
CCW. familiar with transponder integrated circuitry,
or by the regional Collins Service Center.
h. IDENT and Self Test.
(1) SetTransponder Code Selector-switches 2-30. Vol 1 for maintenance of

Refer to HMI
to any code other than 0000, 7600, 7700, and 7777. wiring and harnesses, electricalbonding, and
repair of electrical connectors.
(2) Activate IDENT switch on transponder.
The IDENT pulse lamp on the ATC-GOOA shall 2-31. Refer to Collins TDR-950 Transponder
light for a period of 15 to 30 seconds.
Instruction Manual 523-0766464 for trouble-
(3) SetATC-GOOApower switchOFF. Set shooting information, component repair and
transponder function selector switch to TST. The adjustment, power output measurements, detailed
REPLY lamp on the transponder shall light. test and alignment procedures and required tools.
(4) Holdtransponder function selector 2-32. REMOVAL/INSTALLATION.

switch in the TST position and verify dimming of
the REPLY lamp is accomplished by turning the 2-33. COMPONENT REMOVAL.
IDENT knob.
i. Equipment Shutdown. r~lCA UT ION

(1) Set transponder function selector switch
to OFF. Ensure that electrical power is off.
(2) Open XPDR circuit breaker on circuit

a. To remove transponder:
breaker panel.
(1) Using a 3/32 inch Alien wrench, loosen
(3) On switch panel, set BATT-OFF-EXT
front panel locking screw (1, fig. 1-1) by turning
switch to OFF.
screw counterclockwise.
(4) auxiliary power
Disconnect unit from
(2) Carefully slide out transponder.
helicopter external receptacle 5100. (Transponder will disengage from 15 pin block
(5) Disconnect test equipment and stow connector and antenna connector receptacle.)
ATC-GOOA Test Antenna, 34 dB pad, and coaxial
b. To remove mounting tray:
cables in handling case.
(1) Disengage P48 connector (6, fig. 1-1)

by removing retaining ring (3) and washer (4).
2-25. Other than procedures outlined under
(2) Disengage conversion kit (17) by re-
Operational Check (para 2-19) andInspection (14).
moving screws
(para 2-26), troubleshooting the TDR-950 Trans-
ponder system is limited to interconnecting (3) Disengage P47 block connector (16) by
wiring, cables, and components and is outlined
removing two screws (13). Push block connector
in table 2-2. For troubleshooting information
out through opening in back of tray.
pertaining to the transponder itself, refer to
Collins TDR-950 Transponder Instruction Manual
523-0766464, (4) Remove antenna cable (5) from clamp
(20). All electrical connections are now free
2-26. INSPECTION. from mounting tray.
2-27. prevent convenient

Panel structure will
access transponder interconnecting compo-
to (5) Remove the two flat head recessed
nents. However, system should be inspected at screws (24) from inside front of tray.
regular intervals. Inspection checks that shall
be performed as part of the regular helicopter (6) Remove two nuts (26), washers (25),
maintenance program are listed in table 2-3. and screws (24) attaching tray to mounting
brackets.
2-28. REPAIR.
(7) Remove mounting tray.
2-29. On an organizational level there are no
maintenance functions for the TDR-950 Trans- c. To remove antenna:
ponder itself. If a malfunction cannot be cor-
rected by maintenance of interfacing components, (1) Disconnect P50 antenna cable con-
the transponder unit must be replaced. All nector (10, fig. 1-1).
2-7
Table 2-2. Transponder system troubleshooting
No response when unit Master power switch OFF Set master power switch to BATT.
is turned on
Unit controls not set properly Refer to operating instructions and

reset controls.
Defective circuit breaker Replace circuit breaker.

(CB109)
Loose or broken connector Repair pints) or replace connector.

pints)
Open or shorted wire in wire Repair wire or replace wire harness.

harness
Loose grounding lead con- Tighten connection.

nection (E23)
Defective circuit or com- Replace transponder unit.

ponent in transponder unit
Failure during operation Tripped circuit breaker Allow unit to cool down (approximately
2 minutes) and press circuit breaker
to ON position. If circuit breaker
trips again, repair short in intercon-
necting wiring.
Leave unit off, troubleshoot and repair

as required.
Lodse connectors or contacts Check and tighten connectors. Secure

contacts.
Open or shorted wire in wire Repair wire or replace wire harness.

ha~nesa
Damaged or defective coaxial Repair or repla~e cable.

cable
Intermittent operation Loosened or damaged coaxial Check cables, connectors and wire
during flight cable, connector or wire harness. Repair or replace as
harness required
Faulty transponder unit Replace transponder unit.
2-8
Section 2
Table 2-3. Transponder system inspection
Items/Components Inspect For
Mounting tray, enclosure Scratches, dents, corrosion, rust, bare spots on painted sur-
faces, loose or missing attachments. Secure attachment of
transponder unit.
Secure attachment to panel structure, physical damage, rust or

Mounting tray brackets
corrosion.
Transponder control panel Rust, corrosion, illegible markings, loose or missing knobs,
broken indicator windows, sticking or inoperative controls, burned
out lamps.
Antenna cable connectors Secure connection, loose or distorted sockets, cracked or
damaged cases.
Coaxial cables Crimped or damaged outer shield, worn or frayed insulation.
Antenna Secure attachment to structure, rust corrosion or other

contamination.
NOTE
Accumulation of oil film or other foreign material

in and around the transponder antenna may cause
transmitter frequency pulling. For preventative
measures against contamination buildup, refer
to Section II (Installation)of Collins TDR-950
Transponder Instruction Manual 523-0766464.
Wire harness Evidence of overheating, worn or frayed insulation, loose terminal
lugs or splices, missing identification labels.
Block connector Secured attachment, cracking or damaged, secured wire
(component of wire connection.

harness)
Power conversion kit Secured attachment, secured wiring and soldered contacts.
(components of wire
harness)
Ground wire Secured attachment at block connector and E23 ground connection.
(component of wire
harness)
2-9
(2) Remove antenna mounting nut (fig. 2-3). tray (see figure 2-2). From front, position shim
washer (4, fig. 1-1) over connector and secure
in place with retaining ring (3).
(3) Remove antenna.
2-34. wire harness and coaxial

(2) Route cable (5) through clamp (20)
To remove
attached to back of mounting tray.
cables, disconnect wire harness from terminal
blocks and ground connection and temporarily
free tie straps and clamps as required.
(3) With antenna cable (8) in hand, engage
549 connector (9) with P49 connector (7).
2-35. COMPONENT INSTALLATION.
(4) Route cable (8) along structure at

lower left of instrument panel to copilots under-
CAUTION seat compartment.
Ensure that electrical power is OFF.

CAUT ION
a. To install mounting tray: Excessively sharp bends in the antenna cable

may result inreduced power output and a
decrease in effective range.
(1) Position mounting tray (27, fig. 1-1)
and attach to brackets using two screws (24),
washers (25) and nuts (26).
(5) Install antenna per figure 2-3.
(2). Attach front of tray to panel with two

screws (24) CA UT ION
Ensure good bonding between antenna body

b. To install wiring harness assembly: and aircraft skin. The inside surface of
aircraft skin must be clean and free of paint
and oxidation.
(1) Attach conversion kit (17, fig. 1-1) to
back of mounting tray with two screws (14). (6) Attach connector P50 (10) from cable
in step (4), to antenna.
(2) From conversion kit, attach wire
TDR950clC20 to terminal block TB300, pin 2B d. To install transponder:
and TDR950,2A20 to terminal block TB502,
pin 5F. (See figure 2-4.) NOTE
Before inserting transponder, ensure that

front leg of locking pawl is in the down posf-
NOTE tion (turn locking screw (1, fig. 1-1)
counterclockwise)
Ensure wires TDR950-1D20 and TDR950-
2B20 from conversion kit to block connector (1) Slide transponder in mounting tray
aresecurely connected, ensuring engagement with guide pins and block
connector.
(3) Attach block connector P47 (16) to back

CAUT ION
of mounting tray with two screws (13).
Do not force unit into mounting tray. If dif-

(4) Attach ground wire TDR950-3A20N
ficulty is experienced, remove transponder
from connector block. (See figure 2-4.) unit and check rear connector and guide pins
for proper installation.
c. To install antenna coaxial cables:
(2) To lock transponder in place, turn
(1) Position coaxial cable connector P48 locking screw clockwise with a 3/32 inch Alien
(6, fig. 1-1) into opening in back of mounting wrench.
2-10
CSP-084
P952
P954
TDR 950
TDR4A
TRANSPONDER
56a(OHM) 15W RESISTOR

CPN 747-2172-080
J951
LIGHTDIMMER 13t--JUMPER TDR3A20 (TB5O2-3E)

1 8119
628-8108-001
14VDC t--TDR5A22-------IO( VOLTAGE
Iq
CURRENT CONFIGURATION
GNDI 1 ~(j)l CONVERTER
(P952) CPN 357-7532-030 COAX 900 PL1JG I TDR6A2;51 (E321

FURNISHED WITH 628-5612-001 INSTALN KIT I
TDR2A22 (TB502-1B)
ALT. PIN I
KC-59-l~l TDR1A22N (E?2)
TDROA
P952 1 I r I 1 P954
M171028-AG058 CABLE COAX
ji 56t
KC-59-101 COAX PLUG (P954)
1
LI~
47-1003-2
TDR-950
TRANSPONDER
P5O (Kt-59-27D) (KC-39-51) J49 (CPN357-75~2-010) PB8 (CPN622-2O92-OO1)
42~-Dn-71J
P49 (KC-59-218)
GROUNO
TB30O-2
CBlOs B
XPDR
,--~liff)50-1B20----(A B~TDR950- 12a 30W
TDR950-1D20~1111 14V DC IN
P-616-J T8502-5
28V
BUS ri~"
5A
2
TDR450-lii20-~ E~--l !--L52iiRZ-
50" 65W
CONVERSION
TDR950-2820--~131
(CPN372-7513-080) P47
LIGHT DIMMER
DIMMER CONTROL TB2 T85O2-4 i KIT

(CPN628-5673-001) EARLYCONFIGURATION
26V VARIABLE L523D22
Figure 2-4. Transponder interconnect diagram
2-36. WIRING AND SCHEMATIC DIAGRAMS. Table 2-4. Weight and balance data
2-37. Figure 2-4 shows the TDR-950 Trans- Longitudinal Longitudinal

ponder system interconnect diagram. For sche- Weight Arm Moment
matic diagram of the entire avionics system, (pounds) (inches) tin. -lb/100)
refer to Opt Eqpt CSP-038.
Added 2. 9 45. 9 I. 33
2-38. WEIGHT AND BALANCE.
Removed O O O
2-39. Weight and balance changes resulting from
installation of the TDR-950 Transponder system
are listed in table 2-4. Changed +2. 9 +45. 9 +1. 33
2-11/2-12
CSP
087

and
Maintenance Insfrvcfions
with initial Insfcrllation instructions
FOR
FLOAT LAMP ASSEMBLY
Part No. 369D292032
Hughe. Hesmpters arnaumnu~aara/.uaxw

IVI FG I
INTRO
CSP-087
IN)EII LATBLI CI(ANCLD )*GEI, DEI1IOI C*CtS.

LIST OF EFFICTIVE PAGES THE ASTLRlsK (NDICAILI CAGES CWANGLO. AOOED. OR DLLLTED OV THE CURRENT CHARGE.
Page Issue
Title......... Original
Athru B.....,. Original
CBlank....,.. Original
i............ Original
ii Blank Original
FI1.......... Original
F-2 Blank..,... Original
l-1Ulrul-3 Original
1-4 Blank...... Original
2-1thru 2-8 Original
3-10 Blank Original
Opt Eqpt Manual
and is intended for useby personnel responsible for the maintenance of Hughes Helicopters. Periodic
revisions.
Hughes Helicopters
Attention: J. J.Dillon, Commercial Service Publications

2/T7B
Originator
Address
Boole Identification: Date:
Figure Number(s)
nemarks/~ecommendations
RECORB OF REVISIONS
CSP-087
MFG REV

REV NO
TABLE OF CONTENTS
Sectio? Pa~r
FOREWORD.... F-l

Revisions F-l
r-1. Scope and Contents...... 1-1

List 1-1
1-5. Illustrations
Usable on Code 1-1
2 MAINTENANCE MSTRUCTIONS.. 2-1
2-1. General 2-1

2-9, Inspection 2-1
2-13. Functional Test........ 2-4
2-15. Repair...........-. 2-5
2-17. Wire Identification
Numbers,........... 2-5
2-19. Lamp Removal......... 2-5
2-21. Lamp Replacement...... 2-5
2-24. Lamp HousingRemoval... 2-5.
TABL.E OF CONTENTS
Section Page
2-26. Lamp Housing

Replacement 2-5
2-28. Lamp Assembly
Adjustment 2-6
2-31. Float Lamp Relay
Removal 2-6
2-33. Float Lamp Relay
Replacement 2-7
2-35. Float Lamp Switch
Removal 2-7
2-36. Float Lamp Switch
Replacement 27
2-37. Float Lamp Circuit
Breaker SwitchRemoval 2-7
2-39. Float Lamp Circuit Breaker
Switch Replacement 2-8
3 INSTALLATION ~STRUCTIONS.. 3-1
3-1. General 3-1

3-5. Fuselage Modifications 3-1
3-6. Doubler Installation..... 3-1
Relay Installation. 3-5
3-13. Circuit Breaker Sw;tct~
Installation 3-6
3-16. Float Light Switch
Installation 3-6
3-18. Wiring Installation...... 3-7
3-20. Welghtand BalanceData.. 3-9
II
i/ii
FOREWORD
F-l. PURPOSE AND CONI"NT OF THIS F-3. APPLICABILITY.

MANUAL.
F-4. The floatlamp assembly is applicable to
the 369D, 369HS, and 369HM helicopters.
F-2. This manual supplements information F-5. RELATED PUBLICATIONS.
contained in the Basic Handbook of Maintenance
Instructions, Volume 1 (HMI Vol 1) and the of HMI Vol 1 and 369D IPC as required to
Illustrated Parts Catalog (269D IPC). It
contains instructions for initial installation
and maintenance of the float lamp assembly,
P/N 369D292032. Weight and balance data is
included. This manual also contains a parts List F-8. Changes and revisions to the contents of
for procuring replacement parts for the float this manual are made as defined in Section 1,
lamp assembly. HMI Vol 1.
F-1/F-2
CSP-076 Opt Eclpt Manual Section 1
SECTION 1
1-1. SCOPE AND CONTENTS. 1-5. lLLUSTRATIONS.

1-6. An isometric illustration is provided for
means of text (parts list)and companion illustra-
the group assembly parts list. The illustration
tion, a complete parts definition of the 369D292032
is exploded to the extent necessary to show parts
floatlamp assembly manufactured by Hughes
parts relationship for the complete float lamp
assembly
NOTE
The illustrated parts list is organized and
presented in the same manner as the 369D
1-8. The USABLE ON CODE column located on
Series Illustrated Parts Catalog (369D IPC).
side of the group assembly parts
For information of use, refer to the 369D
the right-hand
list pages indicates the effectivity of parts by air-
IPC.
craft serialnumber. In many cases two different
1-3. GROUP ASSEMBLY PARTS LIST.

parts are listed, representing the original
one
installation and another representing an improved

1-4. The parts list furnishes information for replacement item. Alphabetic codes are used to
procuring replacement parts for the float lamp indicate the aircraft serial number applications
assembly and shall not be used for any other of a given part. When no usable on code is listed,
purpose. items are understood to have full effectivity.
1-1
iiII
1C
3
?~il:
I
OjI r
~_;-.-
Y
35
s~
20
to
32 21
O
I
II
25 19
I ^I -
a
I S1
I" i
47-986
Figure 1-1. Float lamp assembly
1-2
Section 1
CSP-OBI Opt Eqpt Manual
UNITS USABLE
FIG.
DESCRIPTION PER ON
INDEX PART
ASSY CODE
NO. NO.
1
1-1- 369D292032 LAMP ASSY AND INSTL, FLOAT.......
1
-1 369D2404 DECAL
4
-2 AN960PD6L WASHER
4
-3 ~1351957-27 SCREW...........
1
-4 369D292032-5 PLATE
1
-5 M825244-35 CIRCUIT BREAKER
3
-6 AN960PD6L I WASHER
-7 MS51957-27 SCREW
-8 MS21043-08 NUT..............
1
-9 AN9 60PD8 L I WASHER
-10 MS51957-43 SCREW
for369D292032-5) 1
-11 369D292032-9 PLATE (Alternate
1
-12 369D27308 1 PLATE
-13 8868K1M0D SWITCH
1
V47ZA7 VARISTOR........
-14 MS21043-3 I NUT
15 AN9 60PD10 L WASHER
-16 NAS1403-2 I SCREW
-17 MS24 166D RELAY
-18 MS2 1042-4 NUT
-19 AN960PD416L I WASHER
-20 NAS1057T4-082 I SPACER
-21 NAS 1304-19 BOLT
2
369D292032-7 LAMP ASSY........
2
-22 369D292032-8 LAMP HOUSING
2
-23 4580 1.. LAMP.........
AR
-24 MS20470AD3 I RIVET
-25 MS20615-3M4 I RIVET
-26 MS20615-4M6 I RIVET
-27 NAS 1424-03 PIN..........
-28 MS25281-6 I CLAMP........
-29 3 69D2 92032 1 I BRACKET
-30 369D292032-2 BRACKET
-31 NAS557-6 GROMMET.......
-32 MS2 1043-3 NUT
-33 AN960PD10L WASHER
-34 NAS13 03 7 BOLT
-35 369D292032-3 DOUBLER....
1
-36 369D292032-4 DOUBLER......
1-3/1-4
Section 2
SECTION 2
MAINTENANCE INSTRUCTK)NS
2-1. GENERAL. 2-5. The lamps are rigidly installed in the stag-
gered array shown in figures 2-1 and 2-2. The
2-2. provides descriptions and
This section left lamp is depressed 20 degrees below hori-
maintenance information for the float lamp assem- zontal; the right, 40 degrees below. This
arrangement provides an eliptical light pattern
bly. The coverage is intended to be sufficient to
cope with all problems specifically related to this for a landing approach and for hovering.
forward
equipment. Each lamp develops 400, 000 candlepower at

450 watts, 28 V de. The approximate total spread
2-3. DESCRIPTION. of each beam is 13 degrees horizontally and
14 degrees vertically down to 40, 000 candlepower,
2-4. The float lamp assembly consists of the 10 percent of the maximum candlepower. The
parts shown in figure 1-1 andlisted in the illus- average life expectancy of the 4580 lamp is
trated parts List, Section 1 of this manual. The 10 hours.

float lamp assembly provides a flood of light
below and ahead of the helicopter so the pilot can is located on the
2-6. The float lamp switch
observe and assess the suitability of a landing Either the LDG LT or
pilots collective stick.
site without the aid of ground-based lighting. The be selected. The
FLOAT LT position can con-
assembly consists of two PAR 46, USASI number tact rating is 5 amperes, resistive load, at
4580 lamps installed at station 137. 50 (see fig-
28 V de.
ure K307 mounted on the inner side of
2-1), relay
the front panel of the pilots seat structure lower
The FLT LDG LT circuit breaker switch
section, FLT LDG LT circuit breaker switch 2-7.
(CB140) installed in the lower right or lower left (CB140), pushbutton reset type, is rated at
corner of the instrument panel, and the LDG 35 amperes. The circuit breaker switch may be
LT-FLOAT LT selector switch (S32) which is located in either the lower right or lower left
mounted on the pilots collective stick. corner of the instrument panel.
CB140~
TB101
WIRE L522A10, FLOAT LAMP

ASSEF1BLIES
K307
WIRE L522B10
STA
137,50
47-100Y
Figure 2-1. Float lamp assembly component configuration
2-1
CAP SCRE\J 1/4-20x

3/4 IN, SPLIT WASHER I RNF 100x3/8 SLEEVE SEAL WIRE HARNESSES
AT LAMP HOUSINGS
,30 BOTH SIDES
USING 140 RTV
BASE
NUT
\e F 100x1/2 SLEEVE
SCREW 6-32x1/4 IN,

INTERNAL LOCK-
WASHER
CLOTH
SEAL ALL LAMP

JOINTS USING INSTALL LAMPS APPROXIMATELY
140 RTV AT THE ANGLES SHOWN
47-1005
Figure 2-2. Float lamp sealing and adjustment data
TB101
1
DS1~9 2
Al A2
1)1 35A O-- L522810
4
CBlqO
L52 R10V47ZA7
JUMPER
20 GAUGE
VARISTOR
X1
K307 L522E12 L522F12

5# CR37
28 VDC BUS
X2
L522C20
1 2
DS150
PILOTS COLLECTIVE STICK P113 J113

L522G10N
(S1O6)
STAREOF
FLOAT LT,
1
3N02A321L
L522D20
MS25036-153
TERMINAL
L123B16 -------I D
J
d
LDG, LT. MS25036-149
(S32)
TERMINAL TO LANDING
L104C20 C
LIGHT ASSEMBLY
(S1011) RPM TRIM
47-1006
Figure 2-3. Float lamp assemkly wiring diagram
2-2
Section 2
CSP-087 Opt EQpt Manual
MACHINISTS CCINOMETER
METAL RULE
47-1014
Figure 2-4. Machinists clinometer in position for lamp adjustment
2-8. Figure 2-3 is the wiring diagram of the float lamps can be replaced before they fail. A record
lamp assembly. Interconnecting circuit diagrams ofoperating time should be incorporated into the
are provided in Section 20 of the basic handbook regular aircraft inspection log.
of maintenance instructions, HMI Vol i. When
switch S32 is set to FLOAT LT, +28 V de from
terminal board TB101 passes across circuit
CAUTION
breaker switch CB140, to terminals A and X1 and
through the solenoid to terminal X2 of relay K307, Before commencing aninspection or repair,
through contact 5 of connectors 5113 and P113, to ensure that MASTER helicopter primary
terminals 1 and 2 of switch S32, back through power switch (S2) and LDG LT, FLOAT LT
terminal D of connectors P113 and 5113 to ground switch on pilots collective stick are set to
at terminal E9. With relay K307 energized, OFF.
+28 V de passes from terminal Al to the arma-
1. Inspect lenses for cleanliness.
ture, to terminal A2 of the relay, to terminal 1
of each of the parallel connected lamps DS149 and
DS150, through their filaments to terminal 2, 2. Inspect lenses for cracks. Replace lamp
then to ground at terminal E12. ~se of the remote with cracked lens. Refer to paragraph 2-19.
solenoid relay K307 protects the switch contacts
from the high lamp current output from the 3. Check beam angles. Left lamp: -20 de-
terminal board and assures delivery of a maximum grees. Right lamp: -40 degrees.
of current to thelamp filaments. Varistor,
CR37 (fig. 2-4), prevents the relay solenoid from Inspect seal of wire
4. harness at lamp
developing a.transient overvoltage developed when housing. See figure 2-2.
switch S32 is oDcned.
5. Inspect seal of lamp joints. See

2-9. INSPECTION.
figure 2-2.
2-10. 13i?cause f the limited average service life
of the 4580 lamps (10 hours), th~ operator should 6. Inspect grommet at buntline -2. 50 (31,
consider maintaining arecord of usage so the fig. 1-1).
2-3
7. Inspect connection of wire L522H10 to 2-11. TROUBLESHOOTING.

terminal 4 of terminal board TB101.
2-12. Table 2-1 contains symptoms, probable
8. Inspect wire connections to circuit causes, measures required to determine
breaker CB140. causes of neat lamp failures, and recommended
repairs.
9. Inspect security of circuit breaker
mounting fasteners. 2-13. FUNCTIONAL, TEST.
10. Inspect wire connections to relay K307. 2-14. Perform the following tests after installa-
tion or maintenance of the float lamp assembly.
11. Inspect security of relay mounting
fasteners. 1. Set MASTER switch (S2) to ON.
12. Inspect connectors 5113 and P113 for 2. Verify FLOAT LDG LT circuit breaker
security. switch (CB140) is closed (push in).
13. Inspect wire connections to switch S32 3. Set LDG LT, FLOAT LT switch (S32) to
on pilots collective stick. FLOAT LT, and verify both float lamps are on.
Table 2-1. Troubleshooting- float lamp assembly
Symptom Probable Cause Corrective Action
Float lamps fail to MASTER switch (S2) open. Set MASTER switch to ON.
come on.
FLOAT LDG LT circuit Press and reset FLOAT LDG LT cir-

breaker open. cult breaker. If circuit breaker
refuses to remain set, refer to para
2-10, step 10, and 2-37.
FLOAT LDG LT circuit Replace circuit breaker. Refer to

breaker defective, para 2-37.
Lamps broken or burned Replace lamps. Refer to para 2-19.

out.
Defective LDG LT, Replace switch. Refer to para 2-35.

FLOAT.LT switch.
Defective relay. Replace relay. Refer to para 2-31.
Loose wire L522H10 on Tighten wire connection.

4, terminal board TB101.
Loose wire at terminal 1 Tighten wire connection.

or 2 or circuit breaker
switch CB140.
Loose wire at terminal Al Tighten wire connection. Refer to

or A2 of relay K307. para 2-31.
Loose wire L522B10 at Righten wire connection. Refer to

terminal 1 of lamp DS149. para 2-19.
Loose wire L522G10N at Righten wire connection. Refer to

terminal 2 of lamp DS150 para 2-19.
or ground terminal E12.
Both float lamps flicker. Loose wires at terminals Tighten wire connections as required.
indicated above. See entries above.
One float lamp flickers. Broken lamp filament, or Replace lamp, refer to para 2-19, or
loose wires at terminals tighten wire connections as required.
indicated above.
One or both lamps dim. Loose wire at terminals Tighten wire connections as required.
indicated above. See entries above.
2-4
4. Set switch S32 to LDG LT, and verify 1. Inspect fiberglass abrasion strip for
landing light is on. Set switch S32 to OFF. security of attachment. Refer to table 3-1 for
material descriptions.
5. Set MASTER switch to off.
2. Inspect RNF100X1/2 insulating sleeve on
2-15. REPAIR. shank of cap screw (see figure 2-2) for security
of attachment.
2-16. Repair instructions in this section are for
factory installed float lamp assemblies or for 3. Verify security of attachment of cap
installations performed in accordance with instruc- screw and nut.
tions in Section 3 of this manual. Refer to table
3-1 for complete descriptions of consumable 4. Verify security of attachment of bracket
materials required to repair and replace float lamp base.
assembly components. Always adhere to shop
practices which will assure the restoration of the 2-23. To replace a lamp, proceed as follows:
equipment involved to FAA certification standards.
1. Wash lamp with naphtha to remove oil,
2-17. WIRE IDENTIFICATION NUMBERS. grease, or any other foreign matfer, and air dry.
2-18. Before stripping wire insulation for repairs 2. Apply coat of 140RTV around rim of lamp
or replacements, observe wire identification num- and over area opposite cap screw, See figure 2-2.
bers stamped on the insulation and sleeves. When Allow 140RTV to cure.
wire insulation must be stripped back far enough
to obliterate identification numbers, tag the wires 3. Attach wires securely with screws fur-
carefully with their identification numbers. Fig- nished with lamp.
ure 2-3 includes wire numbers, component ref-
erence designations, and terminal letters and 4. Insert lamp into housing, and press lamp
numbers for all electrical components comprising retainer into position.
the float lamp assembly. Before disconnecting
wires whose identification numbes have been 5. Replace four screws and locknuts.
obliterated, determine their identification num-
bers by carefully observing what the wires are 2-24. LAMPHOUS~NC REMOVAL.
connected to (observe both the component refer-
ence designation and the terminal letter or num- 2-25. Refer to figure 1-1, and proceed as
ber) andreferring to that component and terminal follows:

in the wiring diagram. Tag the wires before dis-
connecting them. I. Remove lamp. Refer to paragraph 2-19.
2-19. LAMP REMOVAL. 2. Back off conduit nut and washer (see
figure 2-2).
2-20. See figure 1-1 and proceed as follows:
3. Slide wires out of lamp housing (22).
i. Verify lamp switch (13) on pilots col-
lective stick isset to OFF. 4. Remove fasteners (18, 19, 20, and 21).
2. Remove four fillister-head screws 2-26. LAMP HOUSING REPLACEMENT.

(6-32 X 7/8 in. and locknuts securing lamp re-
tainer to lamp housing. 2-27. Refer to figure 1-1, and proceed as
follows:
3. Strip 140RTV seal from lamp joint (see
figure 2-2), and pull lamp out to gain access to i. Align holes in bracket (29) and lamp
lamp terminal screws. assembly bracket, and install fasteners (18, 19,
20, and 21). Do not tighten fasteners.
4. Remove two lamp terminal screws to
disconnect wires.
2. Insert wires through conduit nut and
2-21. LAMP REPLACEMENT.

washer (see figure 2-2).
2-22. Before installing lamp, inspect interior 3. Strip old sealant from wires and from
of lamp housing (22, fig. 1-1). grommet inside reusable conduit.
2-5
4. Wash grease and oil off wires and NOTE

grommet with naphtha, and air dry.
An alternate method of lamp adjustment is to
5. Draw sufficient length of wires through remove lamp (refer to paragraph 2-19)
the to
conduit to allow access to terminal screws on eliminate the convex surface, and simply
lamp. apply the clinometer vertically across the
open face of the lamp housing.
6. Apply bead of 140RTV inside conduit nut
and allow to cure (see figure 2-2). 2-31. FLOAT LAMP RELAY REMOVAL.
7. After sealant has cured, assemble con- 2-32. The ~oat lamp relay (K307) is mounted on
duit nut and washer on conduit. the rear of the front panel of the pilots seat.
structure lower section. Refer to figure 1-i,
8. Install lamp (23). Refer to paragraph and proceed as follows:
2-21.
1. Verify MASTER switch (S2) is set to OFF.
2-28. LAMP ASSEMBLY ADJUSTMENT.
2. Remove passenger compartment left side
2-29. The left and
right float lamp assemblies foot support fairing.
must be adjusted for a beam angle of 20 degrees
and 40 degrees, respectively, below hori~ontal. 3. Remove two MS35650-306T nuts,
Normally, the helicopter has a nose-up attitude MS35338-100 lockwashers, and AN961-1 washers
while standing. The amount of incliniation must from terminals Al and A2, and disconnect wires.
be measured, with a machinists clinometer or
other suitable instrument, so this factor of in- 4. Remove two MS35649-265T nuts,
clination can be compensated for when setting the MS35338-98 lockwashers, and AN961-6 washers
lamp beam angles. The measured angle of in- from terminals X1 and X2, disconnect wires,
cliniation will be a positive number. The desired and remove variator (CR37). See figure 2-5.
angles of the lamp beams are negative numbers:
-20" and -40". To calculate the resultant angles 5. Remove fasteners (14, 15, and 16) to
at which the lamps must be
set, simply apply the dismount relay.
principle for the addition of signed numbers.
Example: Assume helicopter inclination is +10"

-20"+10"=-10" left lamp resultant angle
-40"+10"=-30" right lamp resultant angle
NOTE I/
~r
One convenient point for measuring the heli-
a
copter inclination is the passenger compart-
ment floor.
2-30. Because the 4580 lamp lens is convex, a

method must be improvised for achieving a flat
surface for the clinometer. One inexpensive
method is as follows:
i. Tape together one end of two six-inch,

longer, metal rules which exactly the
i,
or are same
width. See figure 2-4.
2. Apply rules across lamp retainer, as

shown, so clinometer can be placed vertically S;I
over lens.
3. Apply clinometer vertically across rules,

and adjust lamp to proper computed angle.
117-1007
4.Tighten fasteners (18, 19, 20, and 21,
figure 1-i), and rechedk lamp angle. Figure 2-5. Variator installation configuration
2-6
Section 2
CS"P-087 Opt Eqpt Manual
2-33. FLOAT LAMP RELAY REPLACEMENT. 2-36. FLOAT LAMP SWITCH REPLACEMENT.
2-34. Before installing a new varistor, attach i. Remove one bushing nut, lockwasher,
MS25036-102 terminals as follows: and locking ring from new switch (13, fig. 1-1).
Discard locking ring.

i. Wash varistor leads clean with naphtha,
and air dry. 2. Tighten bottom bushing nut all the way
down, then install lockwashef.
2. Spread leads apart to match relay termi-
nals X1 and X2, and clip any excess. See figure 3. Insert bushing of switch through hole in
2-5. plate (12). Be sure to engage tab on plate with
keyway on switch bushing.
3. Install and crimp MS25036-102 terminals
using MIL-C-22520/5-01 tooling with MIL-C- 4. Install lockwasher and nut on bushing,
22520/5-100 dies. and tighten.
4. Clean panel area with naphtha, and air 5. Clean ends of wires with naphtha, and
dry. air dry thoroughly.
5. Repaint panel area as required. Use 6. Slip new number 12 tubing (MIL-I-631,
acrylic lacquer primer, color green to match type F, form U) over ends of wires.
Fed. Std. 595, number 34151.
7. Solder wire number L522D20 to switch
6. Install relay (17, fig. 1-1) using fasteners terminal i.
(14, 15, and 16).
8. Solder wire number L123A20N to switch
7. Attach wire L522A10 to terminal Al, and terminal 2.
attach one end of 20-gauge jumper to terminal Al,
attach wire L522B10 to terminal A2, and secure 9. Solder wire number L104C20 to switch
with AN961- 1 washer, MS3 5338 100 lockwashers, terminal 3.
and MS35650-306T nuts.
10. Slip insulating sleeving into position.
8. Attach opposite end of 20-gauge jumper
wire toterminalX1, attach wire L522C20 to 11. Reinstall plate (12) and switch assembly
terminalX2, attach varistor to terminals X1 and on collective stick switch housing assembly with
X2, and secure with AN961-6 washers, MS35338-98 four NAS600-3 screws and AN936A4 washers.
lockwashers, and MS35649-265T nuts.
12. Reinstall 369A4215 landing light switch
9. Perform functionaltest. Refer to para- knob, and tighten NAS1081D04-2 setscrew.
graph 2-13.
13.Perform functionaltest. Refer to para-
2-35. FLOAT LAMP SWITCH REMOVAL. graph 2-13.
i. Set MASTER switch (S2) to OFF. 2-37. FLOAT LAMP CIRCUIT BREAKER SWITCH
REMOVAL
2. Remove four NAS600-3 screws and

2-38. The FLT LDG LT circuit breaker switch
AN936A4 washers from plate (12, fig. 1-1), and
(CB140) may be located in the lower left or lower
pull plate and switches away from collective right corner of the instrument panel. installation
stick switch housing assembly.
in the lower left corner requires use of Collins
RCR650 radio receiver forward bracket,
3. Unsolder three wires from switch (13) 369D24216, and plate 369D292032-9. For installa-
terminals. tion of CB140 in the lower right corner, only
plate 369D292032-5 is required. To remove
CB140, proceed as follows:
4. Loosen NAS1081D04-2 setscrew from
369A4215 landing light switch knob, and remove
1. Set MASTER switch (S2) to OFF.
knob.
2. Remove two terminal screws (MS35206-
5. Remove bushing nut and lockwasher from 241) and lockwashers (MS35338-42), and remove
switch, and remove switch from plate, two wires.
2-7
CSP-087
3. Remove bushing nut (MS25082B8) and key engages small hole in panel above bushing
lockwasher (AN936A716S). hole.
4. Draw CB140 rearward from instrument 3. Reinstall and tighten lockwasher and nut.
panel.
4. Remove two terminal screws (MS35260-
241) and lockwashers (111835338-42).
2-39. FLOAT LAMP CIRCUIT BREAKER
SWITCH REPLACEMENT.
5. Attach wire L522H10 to terminal 1 with
fasteners removed in step 4.
2-40. Proceed as follows to install FLT LDG
LT circuit breaker switch (CB140): 6. Attach wire L522A10 to terminal 2 with
fasteners removed in step 4.
1. Remove bushing nut (MS25082B8) and
lockwasher (AN936A716S) from CB140. 7. Tighten all fasteners.
2. Insert bushing of CB140 through hole Perform functionaltest.

8. Refer to para-
in panel (4 or 11, fig. 1-1) so positioning graph 2-13.
2-8
SECTION 3
3-1. GENERAL. consumable and expendable materials listed are

of a commercial nature that could be procurable
3-2. This section provides detailed instructions locally. Alternate, but equivalent, items might
for installing the 369D292032 float lamp assembly. be available, but consultation with Hughes Heli-
This modification may be performed at the dis- copters Customer Service Department is
cretion of the operator, or the helicopter may be recommended.
returned to the factory for modification.
3-5. FUSELAGE MODIFICATIONS.
3-3. REFERENCE DATA.
3-6. DOUBLER INSTALLATION.
3-4. Table 3-1 lists consumable materials and 3-7. Doublers (35 and 36, fig. 1-1) must be
special tools required for the installation.The installed against the inner side of the fuselage
Table 3-1. Special tools and consumable materials
Commercial Product
Item
No. Material Specification Name/Number Manufacturer
1 Aliphatic naphtha Fed Spec. TT-N-95

2 Denatured alcohol Fed Spec. TT-I-735,
type III
3 Acrylic lacquer, Fed Std. 595
colors 17875,
20371, 34151
4 C111 adhesive Stabond Corp.,

Gardena, CA 90249
5 I40RTV Silastic adhesive Dow Coming Corp.,
Midland; MI 48640
6 Stoddard solvent Fed Spec. P-D-680
7 RNF100X3/8, RNF100X1/2 Raychem Corp.,

heat-shrink tubing Menlo Park, CA 94025
8 No. 12 tubing MIL-I-63r, type F,

form U
9 Blue Dykem paint Dykem Co.

Dykem remover, 138 St. Louis, 610 63114
10 Drillbits: 5, 30 31,41, ANSI series
42, 1/16, and 7/16
11 Solder Fed Spec. QQ-S-
571, types R, RMA,
or RA, comp. Sn 60
or 63
12 Tooling MIL-C-22520/5-01
13 Dies M22520 1-01
3-1
Section 3
Table 3-1. Special tools and cansumable materials (Continued)
Commercial Product
item
No. Material Specification Name/Number Manufacturer
14 Dies M22520 1-03
15 Dies MIL-C-22520/5-100
16 Extraction tool MS17806
17 Insertion tool MS17805
skin in the engine bay lower section as shown in

11. Set right doubler (36, fig. 1-1) so
figure 3-1. It will be necessary to remove the edge
of extension on long side is at station 136. 94
369B6006 landing gear brace assemblies. (0. 56
Refer inch from back surface of 369112532
to Section 6, HMI Vol
ring assem-
i, for procedures, bly), see figure 9-2, and the inward side is 0. 20
Install doublers as follows: inch from buntline O.
i.
Remove 12 MS20470AD3 rivets as shown 12. Drill two 0.062-inch holes in skin
in figure 3-1.
Use number 42 (0. 0935 inch) drill through
tworemotely located, existing pilot holes in
bit to remove 3/32-inch rivets.
doubler. Use i/is-inch drill bit.
2. Remove two MS20615M3 rivets with num- 13. Install two Cleco fasteners, then recheck
her 42 drill bit.
accuracy of doubler placement.
3. Remove two MS20615M4 rivets. Use 14.When doubler is properly situated, en-
number 31 (0. 120 inch) drill bit to remove 1/8- large three pilot holes to 0. 096 inch with number
inch rivets. 41 drill bit.
4. Deburr holes as required. 15. Relocate two Cleco fasteners, and en-
large remaining two pilot holes with number 41
5.Clean aircraft structure of all sealant drill bit.
and other foreign materials in area to be in con-
tact with doublers.
3-8. With both doublers held securely in place
by Cleco fasteners, drill remaining rivet holes in
6. Set left doubler (35, fig. 1-1) so
edge of doublers as follows:
extension on long side is at station 136. 94
(0. 56
inch from back surface of 369B2532
ring assem-
bly), see figure 3-2, and the inwa~d side is 0. 20 CAUTION
inch from buntline O.
Insert drill bit into existing holes in stntc-
7.
Drill two 0. 062-inch holes In skin ture frombelow to start new holes. Do not
through
two remotely located, existing pilot holes in attempt to start new holes from inside engine
doubler. Use l/le-inch drill bit. bay. Minute inaccuracies willcause new
holes to be out of tolerance.
8. Install two Cleco fasteners, then recheck

i. Drill holes for MS20470AD3 and
accuracy of doubler placement. MS20615M3 rivets with number 41 drillbit. See
figure 3-1.
9.
When doubler is properly situated, en-
large three pilot
holes to 0. 096 inch with number 2. Drill holes for MS20615M4 rivets with
41 drill bit, number 30 (0. 1285 inch) drill bit.
NOTE
10. Relocate two Cleco fasteners, and en-
To complete the following operation, remove
two pilot holes with number 41
369H6006 brace assemblies. Refer to Sec-
tion 6, HMI Vol i, for procedures.
3-2
MS2O470AD3 RIVET
TYPICAL
,38 TYP,
369H2500
LOWER SECTION
FUSELRGE STRUCTURE 25 TYP
3690292032-4
DOUBLER
MS20615M4 RIVET
TYPICAL
4,25
o o RH
NAS1424 LOCKBOLT
TYPICAL
MS2O615M3 RIVET
MS20470AD3 B~ lo I
TYPICAL
RIVET
MS20470AD3 RIVET
O TYPICAL
II I 1
FWD I ~HELltOPTER
1,00
DRILL NO, 5(,205) DIA THRU 2?50

ms252n-6 CLAMP 2 REQD(1 REQD I I I O
NEARSIDE, 1 REQD FARSIDE)
NAS13O3-7 BOLT 1 REQD lo i O O O
MS21043-3 NUT 1 REQD
AN96OPD10L WASHER 2 REQD
7/16 DIA THRU \117 O~I

LINE HOLE WITH 4,25
NAS557-6 GRDMMET LH
(NYLON) AND BO~ID
IN PLACE
1,80~ STA, 137,50 LOWER SECTION
3690292032-3 1 369H2532 RING ASSEMBLY
DOUBLER ~--2,12--cl
VIEW LOOKING DOWN
(369H6006 LANDING GEAR

BRACES REMOVED FOR CLARITY)
47-1023
Figure 3-1. Float lamp doubler, bracket, and grommet installations
3-3
11. Install brackets in final assembly position

00,20 with Cleco fasteners, and carefully recheck posi-
tion measurements.
12. When brackets are properly positioned,

carefully drill six more pilot holes for lockbolts
-4 helicopter structure where scribed. Use
hguorht.tib
number 42 drill
13. Check brackets and doublers for proper

positioning once again.
-4- 14. When brackets and doublers are properly

positioned, refer to figure 3-1 and scribe center
marks for clamps (28, flg. 1-1).
136.W
15. Drill O. 205-inch holes with number 5
drill bit.
0,062 INCH DIA, 16. Refer to figure 3-1, and scribe hole
PILOT HOLE 5 PLCS
center for grommet (31, fig. 1-1) on left doubler
I
only.
17. Drill grommet hole with 7/16-inch drill

bit.
1~7-1024 18. Remove all Cleco fasteners, and deburr

all holes as required.
Figure 3-2. Float lamp doubler 3-9. Drilling and deburring make it necessary to
alignment details touch up and refinish the parts and the helicopter
structure. All metal surfaces shallbe reprimed
with Federal Standard 595 primer, color number
3. Refer to figure 3-1, and scribe hole 20371, the engine bay shall be repainted insignia
center marks for eight NAS1424 lockbolts. white to match color number 17875, Federal
Standard 595, and the exterior of the aircraft,
4. Drill one pilot hole through helicopter including rivet heads, bolts, and nuts, shall be
structure for each flange of 369D292032-1 and -2 touched up with one or more coats of topcoat to
brackets. Use number 42 (0. 0935 inch) drill bit. match the~surrounding area. After repriming and
before painting, refer to figures 3-1 and 3-2 and
5. Deburr pilot holes as required. proceed as follows:
6. Set left and right brackets in final 1. Install left doubler with 11 MS20470AD3
assembly position (see figure 3-1), and tape rivets.
brackets securely.
2. Install right doubler with 11 MS20470AD3
7. Recheck measurements of bracket posi- rivets.
tions after taping, and correct as required.
3. Install left bracket with four NAS1424-03
8. Mark hole centers
brackets through
on lockscrews,one MS20615M3 rivet, and one
pilot holes in helicopter structure with machinists MS20615M4 rivet.
blue Dykem paint. Allow paint to dry 10 to 15
minutes before removing brackets for drilling. 4.
Install right bracket with four NAS1424-03
lockscrews,one MS20615M3 rivet, and one
9. Remove brackets, dimple center of blue MS20615M4 rivet.
markers and drill one pilot hole on each Range.
Use number 42 drill bit. 5. Install one clamp (28, fig. 1-1) on each
side of left doubler with fasteners (32, 33, and
10. Deburr pilot holes. 34, fig. 1-1).
3-4
3-10. Install grommet (31, fig. 1-1) as follows: 3. Dr~w horizontal line intersecting vertical
line at 3.50 inches from top of seat structure.
i. Wash grommet and area around hole in
doubler with naphtha, and air dry. 4. Draw second horizontal line intersecting
vertical exactly 2. 18 inches from first horizontal
2. Apply heavy coat of type C111 adhesive line.
to grommet and to area around hole in doubler,
and allow C111 to harden 15 minutes minimum. 5. Dimple both center marks with center
punch.
3. When C111 has
hardened, apply thin coat
of C111 tomating surfaces and press together. 6. Recheck hole center dimensions. Center
Allow assembly to air-dry for eight hours marks must be 2. 18 inches apart.
minimum
7. Drill two clearance holes with number 7
4. Install lamp housings as described in (0. 2010 inch) or number 5 (0. 2055 inch) drill bit.
paragraph 2-26. Do not install lamps until wires

are installed. 8. Deburr holes as required.
3-11. RELAY INSTALLATION. 9. Wash area around holes with naphtha and
allow to air-dry thoroughly.
3-12. See figure 3-3, and install relay K307 as
follow s: 10. Touch up exposed metal with acrylic
lacquer, color green to match number 34151,
1. Remove passenger compartment left side Federal Standard 595. Allow paint to dry
foot support fairing. thoroughly.
2. Draw vertical line at exactly 14. 43 inches 11. Assemble and install relay as described
from center of helicopter, buntline O. in paragraph 2-33.
369H2542 20.
SEAT STRUCTURE LH
RELAY
PILOTS LOWER SECTION 14,43
1 REQD,
3,50
2.18
,00
I
VIEW LOOKING AFT DRILL NO, 5(,205) THRU 2 PLCS
TRIM REMOVED FROM NAS1403-2 SCREW 2 REOD
SEAT STRUCTURE FOR CLARITY MS21043-3 NUT 2 REOD
AN960PDIOL WASHER 4 REED V-1028
Figure 3-3. Float lamp relay installation details
3-5
3-13. CIRCUIT BREAKER SWITCH

INSTALLATION. ~S 8
~4
e~
3-14. LEFT SIDE INSTALLATION. Helicopters
equipped with the Collins RCR650 radio receiver 8
can readily accept the circuit breaker switch
(CB140) in the lower left corner because the
C
Collins RCR650 receiver forward bracket
(369B24216) is already installed. For left side
installation, refer to figure 1-1, and proceed as
follow s:
i.
~i
Remove bushing nut (hIS25082B8) and
lockwasher (AN936A716S) furnished with new cir-
cuit breaker switch (5).
~5
2. Insert bushing of CB140 through hole in

panel (11) from rear so positioning key engages
small hole in panel above bushing hole.
3. Reinstall and tighten lockwasher and nut.

47-1029
4. Set aside panel and circuit breaker switch
assembly until wires are installed.
Figure 3-4. Float light-landing light switch
3-15. RIGHT SIDE INSTALLATION. For right plate for pilots collective stick
side installation, refer to figure 1-1 and proceed
as follows:
4. Loosen NAS1081D04-2 setscrew securing

1.Remove bushing nut (MS25082B8) and 369A4215 landing light switch knob, and remove
lockwasher (AN936A716S) furnished with new cir- knob. Retain knob for reuse.
cult breaker switch (5).
5. Loose AN565D4112 setscrew securing
2. Insert
bushing of CB140 through hole in 369A4568 knob on N2governor control switch
panel (4) from rear so positioning key engages (5108), and remove knob.
small hole in panel above bushing hole.
6. Remove bushing nuts (15/32-32) and
3. Reinstall and tighten lockwasher and nut, lockwasher from N2 governor control switch,
and separate switch from plate.
4. Set aside panel and circuit breaker
switch assembly until wires are installed. NOTE
3-16. FLOAT LICHTSWITCH INSTALLATION. Inspect condition of potting on N2 governor

control switch.
3-17. The landing light switch (S105) on the pilots
collective stick must be replaced with a three- 7. Install one nut on bushing of N2 governor
position switch (S32) to accommodate the float control switch; run nut all the way down bushing
lights and the landing light alternatively. Refer to and tighten, then install lockwasher.
figures 1-1 and 3-4, and install new switch S32 as
follow s: 8. Insertbushing through switch plate hole
from rear. Insert in hole identified as N2 GOV,
1. Set MASTER switch (S2) to OFF. INCR, DECR. Be sure to engage tab on plate
withkeyway on bushing.
2. Remove four NAS600-3 screws and
AN936A4 washers from existing switch plate, and
9. Assemble nut on bushing, and tighten.
pull plate and switches away from collective stick
switch housing assembly.
10. Remove bushing nuts, lockwasher, and
3.Unsolder two wires switch S105
on locking ring fromnew float light-landing light
terminals, switch (13, fig. 1-1). Discard locking ring.
3-6
11. Install one nut on switch bushing; run nut 25. Remove protective shell from P113
all the way down bushing and tighten.
26. With MS17806 extraction tool, remove
12. Install lockwasher. spare contact J from insert block.
13. Insert bushing through switch plate hole 27. Strip sufficient insulation and RNF
from rear. Engage tab on plate with keyway on sleeving from 20-gauge wire L522D20 so exposed
bushing. wire can be bent double and still insert fully into
M517803-16-16 contact.
14. Assemble nut;on bushing, and tighten.
NOTE
15.Cover entire length of new wire,
L522D20, with 1/8-inch diameter RNF sleeving, In order to make the 20-gauge wire fill the
and heat sleeve for proper shrink fit at 121" to larger 18-gauge cavity of the MS17803-16-16
130"C (2505 to 270"F). terminal, the wire must be bent double then
twisted just tight enough to comply. Experi-
16. Slip new number 12 tubing (MIL-I-631, ment with minute increments of twist until
type F, form U) over ends of wires. Slide tubing proper fit is obtained. Use 16-gauge wire
down wires out of the way. sample to compare fit with twisted wire.
Proper filling of the cavity is essential for
17. Resolder wire number L104C20 to switch a good crimp connection.
terminal 3, and wash off flux with denatured
alcohol. 28. Crimp properly fitted wire with M22520
1-01 basic crimping tool and M22520 1-03
18. Resolder wire number L123A20N to positioner.
switch terminal 2, and remove flux.
29. Install properly crimped wire-terminal
19.Solder new wire number L522D20 to assembly into insert hole J. Use MS17805 in-
switch terminal i, and remove flux. sertion tool.
20. Slip insulating sleeving over terminals. 30. Reinstall shell.
21. Insert new wire (L522D20) down through 3-18. WIRING INSTALLAT~ON.
stick, and incorporate it into cable.
3-19. New wires for the float lamp assembly
NOTE must be routed for incorporation into existing
harnesses. Clean all stripped wires and termi-
It is necessary to partially disassemble the nals with solvent, Federal Specification P-D-680.
pilots collective stick in order to incorpo- Proceed as follows:
rate wire L522D20. Refer to Section 7,
new
HMI Vol 1, for instructions, and figures i. Dismount connector 5113, and remove
107 and 108 in the Illustrated Parts Catalog. protective shell.
22. Install plate and switch assembly on 2. Remove spare contact 5 from insert
pilots collective stick switch housing assembly block. Use MS17806 extraction tool.
with four NAS600-3 screws and AN936A4
lockwashers. 3. Strip sufficient insulation from wire
L522C20 so exposed wire can be bent double and
23. Install knob from landing light switch on still insert fully into 16-gauge MS17804-16-16
new float light-landing light switch. contad. Refer to NOTE following step 27 above.
24. Remove 369B6573-35 pilots collective 4. Crimp and install contact with same
stick cover, and disconnect connector P113. tools described in stepb 28 and 29 above.
NOTE
5. Reinstall shell, and remount connector.
Connector P113 is located at the base of the

pilots collective
stick. It mates with 5113 6. Select best cable route to terminal X2
which is mounted on the left side of the of float lamp relay K207, and incorporate wire
pilots seat structure lower section. L522C20 into cable. See figure 3-3.
3-7
NOTE NOTE
Use MlL-C-22520/5-01 tooling with MIL-C- When performing steps 20 through 29 below,
22520/5-1.00 dies for crimping all MS25036- allow sufficient length of wires L522B10,
series terminals in float lamp wiring L522E12, L522F12, and L522G10N so lamps
in stallation. can be removed from housings to gain access
to lamp terminals.
7. Terminate wire L522C20 at relay
terminal X2 with MS25036-102 terminal. Include 20. Pass wires L522B10 and L522G10N
one varistor lead on terminalX2, and tighten through grommet in left doubler (see figure 311),
fastener. conduit nut, washer, and conduit of left float
lamp.
8. Terminate one end of a0-gauge jumper
with MS2 503 6- 103 terminal. 21. Terminate wire L522B10 at lamp DS149,
terminal i, with MS25036-156 terminal. Do not
9. Attach end of jumper with MS25036-103 tighten fastener.
terminal to relay terminal Al. Do not tighten
fastener. 22. Pass wires L522E12 and L522F12
through left lamp conduit, nut, washer, and
10. Terminate opposite end of jumper with conduit.
MS25036-102 terminal.
23. Terminate wire L522E12 at terminal 1
11. Attach end of jumper with MS2503 6-102 with M825036-156 terminal. Include wire
terminal to relay terminal X1, install opposite L522B10 on terminal, and tighten fastener.
lead of varistor on terminalX1, and tighten
fastener. 24. Terminate wire L522F12 at lamp termi-
nal 2 with M525036-156 terminal.
12. Install panel and circuit breaker assem-
bly with fasteners (2 and 3, or 6, 7, 8, 9, and 25. Combine wire L522G10N with wires
10, fig. 1-1). L522E12 and L522F12 in same tubing. Wire
L522G10N is to pass out of left lamp housing and
13.Select best cable route from relay termi- into right lamp. housing.
nal Al to float lamp circuit breaker switch CB140,
t~rminal2, and incorporate wire L522A10 into 26. ~Pass wires L522E12, L522F12, and
cable. L522G10N through right lamp conduit, washer,
and conduit nut.
14. Terminate wire L522A10 at circuit
breaker CB140, terminal 2, with M325036-156 27. Terminate wire L522E12 atlamp DS150,
terminal. terminal i, with MSi5036-156 terminal.
15. Terminate wire L522A10 at relay K307, 28. Terminate wire L522F12 at lamp termi-
terminal Al, with MS25036-112 terminal. nal 2 with MS25036-156 terminal. Do not tighten
Include end of jumper with terminal MS25036-103, fastener.
and tighten fastener.
29. Terminate wire L522G10N at lamp
16. Combine wires L522B10 and L522C10N terminal 2 with M525036-156 terminal. Include
in RNFx3/8 tubing, wire L522F12 on terminal, and tighten fastener.
17. Combine wires L522E12 and L522F12 in 30. In engine bay,.terminate wire L522G10N
RNFx3/8 tubing. at ground terminal E12 with M525036-114
terminal.
18. Let left float lamp be DS149. Select
cable route from relay K307, terminalA2, to
lamp DS149, terminal i, and incorporate wire NOTE
L522B10 into cable.
Ground terminal E12 is located in front of
19.
Terminate wire L522B10 at relay K307, the engine in the center of the bulkhead on
terminal A2, with MS25036-112 terminal. stiffener 369B2523-15.
3-8
CSPc087 Opt Eqpt Manual Section 3
Si. Thoroughly clean wire harnesses at lamp 97. Terminate wire L522H10 at circuit
housings and clean washers and inside of conduit breaker switch CB14~0, terminal i, with MS25036-
nuts with Stoddard solvent, Federal Specification 156 terminal.
P-D-680.
38. Perform functionaltest. Refer to para-
32. ApplycoatlngofDow CorningA-4b94 graph 2-13.
primer to harnesses and inside of conduit nuts.
3-20. WEIGHT AND BALANCE DATA.
33. Apply 140RTV sealant to harnesses at
lamp housings, on washers, and inside conduit 3-21. Weight and balance changes resulting from
nuts. Allow sealant to cure at room temperature. installation of the float lamp assembly are listed
in table 3-2. After installation of the float lamp
3.4. After 140RTV as cured, assemble con- assembly, incorporate changes to the helicopter
duit nut and washer on conduit. weight and balance record as instructed in HMI
Vol 2.
35. Select best cable route from circuit
breaker switch CB140, terminal I, to terminal
Table 3-2. and balance data
Weight
board TB101, terminal4, and incorporate wire
L522H10 into cable.
Weight Arm Moment
NOTE (pounds) (inches) tin. -lb/100)
Terminal board TB101 is mounted on under- Added: 4.8 115. 6 5. 55

side of instrument panel.
Deleted: 0.0 0.0 0.0
36. Terminate wire L522H10 at TB101,

Change: +4.8 115.6 +5.55
terminal4, with MS25036-112 terminal.
3-9/3-10
CSP
089

and
Mc~infenance Instrucfions
with Initial Installcrtion Insfructions
FOR.
DUAL STARTING KIT
Part No. M30308
USED ON HUGHES 5000 (MODEL 389D) HELICOPTERS
Hughes Helicopters. Inc.
COW81582 fssued 1 October 1982

IVI FG I
INTRO
INSEI~ IAIE)I CWANGED PACES. OESTPOY SUPEPSCDEO PACES.

LIST OF EFFECTIYE PAGES THE ASTERISK INDICATES PAGES CHANGED. ADDED. OR DELETED BY THE CURRENT CHANGE
Page Date
Title............ Original
A thru B......,., Original
CBlank........~.. Original
i............... Original
ii Blank Original
F-l............. Original
F-2 Blank......... Original
1-1 thru 1-3.....,. Original
1-4 Blank........, Original
2-6 Blank,......., Original
3-6 Blank Original
and is intended for use bypersonnel responsible for the maintenance of Hughes Helicopters. Periodic
reader, ally information has been omitted or requires clarification, please direct your comments to this
revisions.
Hughes Helicopters

2/T7B
Originator
Address
Figure Number(s)
B/C
RECORD OF REVISIONS
CSP-089
MFG REV
NO DESCRIPTION ISSUEDATE ATP REVDATEI INSERTEDBY
RECORD OF TEMPORARY REV1SIONS
$e~ DATE REV REMOVE

ATP REV INSERT
TABLE OF CONTENTS
Section Page
FOREWORD F-f
F-l. Purpose and Content ol

Revisions F-l
1 lLLUSTRATED PARTS LIST 1-1
1-i. Scope and Contents...... 1-1

List
1-3. illustrations
2 MAI~NTENANCE MSTRUCTIONS.. 2-1
2-1. General Information,,. 2-1

2-5. Rigging Collective
Controls 2-1
2-6. Inbq.ard Collective Pitch
Control Trim Cover..... 2-1
2-7. Maintenance of Copilots
Collective Pitch Stick 2-1
2-8. Removal of Pilots
Collective Pitch Stick 2-1
2-9. I)isassembly of Pilots
Collective Pitch Stick
(369D Left Position) 2-1
2-10. Inspection of Pilots
(Left Pos~Hon)......... 2-3
TABLE OF CONTENTS
Section
2-11. Repair of Pilots

(Left Position)........
2-12. Reassembly of Pilots
(Left Position)........
2-13. Installation of Pflot!s
(369D Left Position)
2-14. Adjustment of Gas
Producer Linkage in
Installed Collecttve
Pitch Sticks
2-15. Collective Pitch Stick
Friction
2-16. Electrical Wiring and
Switcl;es
3 INSTALLATION LNSTRUCTIONS..
3-1. General Information.....

3-2. Reference Data
Installation
3-4. Pilots Collective Pitch
Stick
3-5. Replacement of Friction
Adjustment Cam........
3-6. Pilors Collective Pitch
Stick Modlflcat~on.......
3-7. Replacement of Copilots
Collective Pitch Stick and
Inboard Collective Pitch
Stick Socket
3-9. Removal of Copilots
Collective Stick and
Socket
3-10. Installation of Copilots
Assembly
FOREWORD
F-l. PURPOSE AND CONTENT OF THIS is organized to provide comprehensive coverage

MANUAL. This manualsupplements information of entire systems, major equipment groupings.
contained in HMI Vol 1, (CSP-D-8), 369D IPC and major components that are similar or
(CSP-D-4) and Dual Controls Opt. Eqpt Manual associated. Procedures for each of these are
(CSP-018), and contains instructions for initial presented in sequence as defined in Section I,
installation and continuing maintenance for the HMI Vol 1.
dual starting equipment. Weight and balance data
is included. This manual also contains parts lists F-5. USE OF THIS MANUAL. This manual is
for procuring replacement parts for the dual start- for by operators of the Model 369D helicopter
use
ing equipment. equipped with dual starting kit. Although this man-
ual is a separate publication, it should be kept
F-2. APPLICABILITY. The dual startingkitis with HMI Vol 1, HMI Vo12, (CSP-D-3)
for Hughes model 369D 369D IPC and other handbooks listed in Section 1,
applicable use on any
helicopter equipped with optional dual controls. HMI Vol 1 that form the primary information
file for the helicopter.
OPTIONAL E&UIPMENT. For compatibility F-6. RELATED PUBLICATIONS. Reference is
information on which optional equipment may or made to applicable portions of HMI Vol 1 and
369D IPC as required to accomplish instructions
refer to Section 21, HMI Vol 1. contained herein.
F-4. ORGANIZATION OF CONTENTS,. The F-7. LITERATURE CHANCES AND REVISIONS.

contents of this manual are grouped into sections Changes and revisions to contents of this manual
as outlined in the Table of Contents. Each section are made as defined in Section 1, HMI Vol 1.
F-1/F-2
SEeTION 1
1-1. SCOPEAND CONTENTS. This illustrated 1-2. GROUP ASSEMBLY PARTS LIST. The
and companion illustrations, a complete parts replacement parts for the dual starting kit equip-
definition of the M30306 Dual Starting Kit, manu- ment, and shall not be used for any other purpose.
factured by Hughes Helicopters, Inc., Culver
City, California.
1-3. ILLUSTRATIONS. Illustrations arepro-
NOTE: The illustrated parts list is organized vided for each group assembly parts list.
and presented in the same manner as the 369D Each illustration is exploded to the extent
Series Illustrated Parts List (369D IPC). (For necessary to show parts relationship for the
information on use, refer to the 3.69D IPC.) complete dual starting kit installation.
1-1
1 6
Fl
I _
47-1147
Figure 1-1. Dual Starting Kit

1-2
Manual Section 1
CSP-089 Opt Eqpt
UNITS USABLE
FIG.
DESCRIPTION PER ON
INDEX PART
ASSY CODE
NO. NO.
M30306 DUAL STARTING KiIT............. 1

1-1-
1
-1 MS324665-143 PIN, COTTER.......
NUT 1
-2 MS17826-4
BOLT 1
-3 NAS6204-15D
BUSHING............ 1
-4 HS626-4-340
3
-5 AN960PD616 I WASHER
1
-6 HS610C3745 I BUSHING...........
R252T320
WASHER............ 2
-7 AN960PD416L
STICK ASSY, Pilots collective 1
-8 369A7307-603
(Refer to 369D IPC for bkdn)
SWITCH. 1
-9 269A4637 1
1
-10 MS25440-6 I WASHER
PIN 1
-11 MS35672-1
RING. 1
-12 M30306-5
1-3/1-4
CSP-089 C~t E~pt Manual Section 2
SECTION 2
2-1. GENERAL INFORMATION. The dual starting repair inboard collective pitch control trim cover
kit installation modifies the optional 369D heli- as directed in Section 2, CSP-018.
copter dual controls installation (CSP-018) to
permit starting of the helicopter from either the 2-7. MAINTENANCE OF COPILOTS
pilot (left hand) or copilot (right hand) position. COLLECTIVE PITCH STICP Remove, disassem-
Collective friction and throttle friction is adjusted ble, and install copilots collective pitch stick as
using the inboard (copilots) collective pitch stick instructed in Section 7, HMI Vol 1 for 500MD
and is accessible by either the pilot or copilot. pilots collective pitch stick. Refer to Section 19,
With the dual starting kit installed, provisions for HMI Vol 1 for replacement of pitch stick
collective and throttle friction adjustment are switches.
removed from the pilots (left hand) collective
stick. 2-8. REMOVAL OF PILOTS COLLECTIVE
PITCH STICK. Remove pilots collective pitch
2-2. DESCRIPTION. The dual starting kit consists stick according to instructions in Section 7,
of a pilots collective stick assembly (8, fig~ 1-1) HMI Vol 1.
installed in place of the copilots collective pitch
stick, provided as part of the optional dual con- 2-9. DISASSEMBLY OF PILOTS COLLECTIVE
trols equipment, and the inboard collective pitch PITCH STICK (369D LEFT POSITION). (See
stick socket. Hardware necessary to mod.ify the figure 2-1.)
pilots collective pitch stick friction and throttle a. Cut two nylon straps, and remove stick
friction mechanisms is also included. All friction mechanism guard.
switches on the pilots and copilots collective b. Remove setscrews that secure switch
sticks are duplicated. housing.
2-3. REFERENCE DATA. Sections 7 and 19, NOTE: Removal of additional setscrew is also
HMI Vol 1 and CSP-018. required on helicopters equipment with cargo
release mechanism (Opt Eqpt Manual CSP-005).
2-4. TROUBLESHOOTING. Troubleshooting
dual collective controls with the dual start kit c. Cut
nylon strap or twine that secures elec-
installed requires the same procedures as those trical wiring to stick tube. Push wire slack into
in Section 7, HMI Vol 1 for the 500MD stick carefully pull housing and wiring from end
helicopter, of stick tube and disconnect wiring from switches.
(For switch replacement, refer to Section 19
NOTE: When troubleshooting and rigging HMI Vol 1.
collective controls with dual starting kit Remove setscrew and wire guide from for-
installed, the copilots collective pitch stick ward end of stick. Tie string on each wire bundle
must be treated as the 500MD pilots collective to aid reassembly and remove wiring.
pitch stick, and instructions peculiar to the e. Remove spring and Nylafil ring.
500MD copilots collective pitch stick apply Remove grip attach bolts and grip from
to the left hand, or pilots collective stick. stick tube.
g. Remove adjusting nut pin and throttle
2-5. RIGGING COLLECTIVE CONTROLS. Rig friction nut only if stick tube replacement is
collective controls according to Section 7, HMI necessary, or if end play must be adjusted.
Vol 1 and above note. Rigging fixture (1, (Refer to paragraph 2-12.)
table 3-1) must be used. If necessary, extend Remove friction mechanism and guide from
slot in pilots collective friction guide link to stick fitting.
allow proper rigging using the inboard collective i, Remove idler gear from stick fitting.
stick.
NOTE: In following steps, do not remove
2-6. INBOARD COLLECTIVE PITCH CONTROL bearings or pinion unless replacemeht~ is
TRIMCOVER. Remove,install, inspectand necessary.
2-1
h
hi
FRICTION WASHER
o
(FELT)
BACKU P DI SC
THRDTTLE
(METAL)THROmE r\3
GRIP (NOTE 1)
NUT (NOTE 1) FRICTIONhj, COVER
SWITCH HOUSING
SPRING i t(NYLON)
FRICTION DISC
MOUNTING DISTANCE SHIM (CUT)
BACKUP DISC
BEARING (NOTE 3)
U~ETAL)
ATTACH
8~- BOLTS
GAS PRODUCER
CONTROL TUBE
,I NYLAF IL PINION
RING FITTING
NYLON STRAP HOUSING SOCKET
(NOTE (NOTE /o
SETSCREW SHIM WASHER 1)\
5)
SETSCREW(NOTE IDLER GEAR
I
BACKLASH
SHIM o-
STICK
FIT INGSTRAP GEARSHAFT M
!j
NYLON
GUARD g
o BACKLASH SHIM
o
RING j~
(NOTE 3) c
NYLON STRAP f~Uc

GEAR
o CAP
(NOTE 1) WASHER BEARING
PHENOL IC
(NOTE 1)
ADJUSTMENTIa
(NOTE 3)
WASHERS
(NOT~) FRICTION
TEFLON WASHER
STICK TUBE NOTES:
WIRE
GUIDE
I /la METAL
I
II~ i. SURFACES IN CONTACT DURING ROTATION. OR
OTHERW ISE NOTED. TO BE LUBRIGATED WITH
(NOTE
1)WASHER FRICTION
SPACER
1~1OTE 1)
GREASE (1. TABLE 3-2).
2. NEW PH~UOLIC WASHERS ABRADED TO REMOVE
GLAZE.
DRIVE RETA INER 3 BEARINGS INSTALLED WITH GRADE A LOCKING
GEAR GUIDE COMPOUND 12. TABLE 3-2) AFTER SHIMMING

NOTE 6 FOR MOUNTING D I STAN CE AN D BACKLASH.
UI~OTE 4
4. DRIVE GEAR END PLAY 0.002 0. 010 IN.
SETSCREW
5. USED ONLY WITH OPTIONAL E9U I PMENT.
6. LENGTHEN SLOT AS NECESSARY TO PERMIT
RIGGING OF COLLECTIVE CONTROLS. C~
47-1148
Figure 2-1. Pilots Collective Pitch Stick F~xploded View

j. Remove cap from stick housing. tube and install setscrew. When tightened,
Remove gear shaft assembly. Keep back- screw must be flush or not recessed more than
lash shims with gear shaft. 0. 010 inch below outer tube surface.
i. Remove cover from back of stick housing, e. Install gas producer control tube through
m. Remove gas producer control tube through access housing, and through
hole in back of stick
access hole at back of stick housing. Remove stick tube until control tube fitting engages wire
mounting distance shim housing. Remove guide bore. Reinstall mounting distance shims at
adjust pinion gear mounting distance. (Refer to forward side of pinion bearing if removed during
Section 7, HMI Vol I.) disassembly. (One edge of shim must be cut for
installation.)
2-10. INSPECTION OF PILOTS COLLECTIVE
PITCH STICK (LEFT POSITION). NOTE: Stepsf through h below are used to
Inspect bearings for

binding or looseness. determine gas producer control tube pinion
4 Inspect all gears for cracks, and chipped mounting distance (fig. 2-2).
or broken teeth.
Inspect stick tube and gas producer control _f. Install approximate required thickness of
tube for corrosion, deformation and loose rivets. split shims between pinion bearing and housing
to establish gasproducer control tube pinion
NOTE: Pitch stick housing and cap may be mounting distance.
either magnesium or alloy casting. (For cor- Apply 10 pound load pulling gas producer
rosion control and identification of magnesium torque tube forward compressing shims.
or aluminum alloys, refer to Section 2, h. Add, or subtract shims to provide 0. 699
HMI Vol 1.) 0. 709 inch dimension shown in figure 2-2.
Repeat step g during each measurement.
2-11. REPAIR OF PILOTS COLLECTIVE After mounting distance shimming is cor-
PITCH STICK (LEFT POSITION). rect, remove gas producer control tube and apply
a. Replace bearings if corroded, excessively grade A locking compound (2, table 3-2) to out-
worn, or if outer or inner races of bearings side diameter pinion bearing outer race and stick
rotate on mating surfaces and locking compound housing bore. Reinstall controltube, and check
is inadequate to prevent rotation, that compound does not enter bearing and that
Replace loose rivets in gas producer bearing outer race and shims are firmly seated
control tube. against housing bore.
c. Replace friction drive gear or idler gear 3 Using grease (1, table 3-2), lubricate ID
with cracked, chipped or broken teeth, of throttle grip and install grip on stick tube.
d. Replace phenolic friction washers~against Align grip and gas producer control tube fitting
guide if worn to less than 1/32 inch thickness, and install grip attach bolts. When tightened,
Replace friction gear assembly if driven
e. bolts must be at least flush and not recessed more
gear has cracked, chipped or broken teeth. than 0. 010 inch below outer surface of grip.
Replace damaged spacer, h. Check throttle grip for zero end play on
stick tube and that not more than 5 inch-pound-
2-12. REASSEMBLY OF PILOTS COLLECTIVE torque is required to rotate the grip. If these
PITCH STICK (LEFT POSITION). conditions exist, proceed with obelow. If there
p. Check gearshaft bearings in housing cap and is end play, or too much torque is required to
housing for security of outer races (fig. 2-1). rotate the grip, perform steps m, and n_.
Use grade A locking compound (2, table 3-2) to i. Remove grip attach bolts and grip.
install replacement bearings. Use care to pre- m. Insert 3/64-inch-diameter drift punch into
vent compound from entering bearings, and make access hole on forward face of throttle friction
sure that each bearing is seated against its bore nut and drive roll pin from nut and threaded
shoulder, fitting of stick tube.
Using grease (1), lubricate stick tube
b. n. Reinstall grip with grip attach bolts and
interior where gas producer control tube fitting establish zero end play and correct rotational
makes contact, friction (5 inch-pounds maximum) between nut
c. Attach strings routed through stick tube and grip. Using 5/64-inch drill, match-drill
during disassembly, and thread electrical wire stick tube fitting threads to existing pin groove
bundles from plug through exit hole, throttle in nut, and install pin. Clearance between
friction nut, friction washers and discs, and forward end of nut and grip must not exceed
throttle grip, and spring (fig. 2-1). Pull wiring 0. 010 inch.
out through front end of stick tube. e. Establish gas producer control tube pinion
Install wire guide so that it divides switch and shaft assembly bevel gear backlash (fig, 2-a)
wiring: three wires in one cutout and four in the by temporarily installing driven gear, shaft, and
other. Align guide with matching hole in stick two bearings, plus approximate required
2-9
PINION GEAR
MOUNTING DISTANCE
PINION GEAR, _, (0. 699 0. 709 IN.
,_
PINION BEARIN
GAS PRODUCER SPLIT SHIM(S)

TORQUE TUBE (NOTES i, 3)
BEARING
DRIVEN GEAR
--I
BEARING
BACKLASH SHIM(S)
T--
(NOTES 2,3) HOUSING CAP

TOP VIEW
~t- IDLE STOP

NOTE: GRIPMID-TRA
SHIMS SELECTED AS REQUIRED.

STEEL SHIMS PROVIDED IN
-NICLOSED
0.001-, 0.002-, 0.005-, 0.012-,
AND O. 032-IN. THICKNESS.
NI OPEN
BELLCRANK ON INBOARD
15" 1
COLLECTIVE STICK
SOCKETASSEMBLY
~y4?
73"30
\/\\\j i 2050(NOTE5)
CENTERLINE OF GAS
PRODUCER TORQUE
TUBE (NOTE4)
CUTOUT IN
DRIVEN GEAR
NOTES:
i. DETERMINES GEAR MOUNTING DISTANCE.

LEFT SIDE VIEW
2. DETERMINES GEAR BACKLASH; BACKLASH MINIMUM 0. 003 IN.
3. SELECTED AS REQUIRED; STEEL SHIMS AVAILABLE 1N 0.OD1-,

0,002-, 0.005-, 0.012-, AND 0.032-IN. THICKNESSES.
4. ALSO CENTERLINE OF PINION GEAR AND CUTOUT IN DRIVEN
GEAR.
5. CENTERLINE OF CENTER TOOTH ON DRIVEN GEAR.
47-1149
Figure 2-2. Gas Producer Drive Mounting Distance and Backlash

(Pilots Collective Pitch Stick)
2-4
thickness of backlash shims in housing as shown check that both pilots and copilots throttle
in figure 2-2. Temporarily install housing cap. grips are at mid-travelposition. Also at
Add or subtract shims to provide maximum back- mid-travel, twopilots throttle grip attaching
lash of 0. 003 inch without bind in gears. Make bolts should be approximately straight down.
certain that bearings are completely seated in Both grips should be set to and held at these
bores while establishing this backlash positions while socket and stick gearing is
adjustment. interconnected by gas producer interconnect
After backlash shimming is correct, remove torque tube. If mid-travel positions are not
housingcap and gear shaft, synchronized, further adjustment of installa-
q. Lubricate teeth of pinion gear and shaft tion is required.
assembly bevel gear with grease (1, table 3-2).
Apply grade A locking compound (2), to
r. c. Complete insertion of collective torque tube,
secure gearshaft to bearings. Do not allow install cradle cap, position bungee bracket in
compound to enter bearings. With throttle grip mounting position, connect droop control over-
at mid-travel, install driven gear as shown in ride link, install copilots collective stick assem-
figure 2-2. Note that at throttle-grip mid- bly (para 2-7) and install collective bungee
travel, cut out portion of the driven gear is to be (Section 7, HMI Vol I).
opposite pinion gear. (Centerline of center d. Place friction guide in seat structure
tooth of driven gear is two degrees and fifty bracket. Arrange three washers and bushings,
minutes from center of driven gear cutout.) loosely spaced between bracket ears, so that
guide is in line (parallel) with stick. Install
NOTE: With throttle
grip at mid-travel, two attaching hardware.
2-1) are positioned
grip attach bolts (fig. e. Connect electrical plug.
approximately straight down, f. Install outboard collective stick cover
(Section 2, HMI Vol i). Raise and lower stick,
s. Install housing cap on shaft assembly and verify that wiring does not foul.
seat with hand pressure while slowly rotating. g. Remove snap plug from exterior skin,
t- Route wiring through Nylafil ring and rotate throttle and visually check for zero back-
spring, and using solder (3, table 3-2) connect lash between gas producer interconnect torque
wiring to switches on switch housing. tube and hexagonal interior surfaces of drive
u. Position Nylafil ring and spring on grip and gearshaft in stick housing. Eliminate any back-
pull slack from wiring in stick tube through exit lash by tightening pipe plug (Section 7, HMI
hole at bottom of tube. Attach switch housing to Vol 1) in end of torque tube; zero backlash is
grip with setscrews. required at both ends of tube.
v. Secure wiring to stick approximately one h. Check that copilots stick throttle grip is at
inch aft of exit hole using nylon strap or twine mid-travel when pilots stick throttle grip is set
(9, table 3-2). to mid-travel. If not, adjust collective pitch
w. Place friction mechanism guard on stick stick gas producer control linkage (para 2-14).
tube and secure with two nylon straps.
2-14. ADJUSTMENT OF GAS PRODUCER

2-13. INSTALLATION OF PILOTS COLLEC- LINKAGE IN INSTALLED COLLECTIVE
TIVE STICKS. Adjust linkage as described in
(See figure 2 -2.) Sectionl, HMI Vol 1.
a. Lubricate stick housing socket with grease
(1, table 3-2). 2-15. COLLECTIVE PITCH STICK FRICTION.
b. Install stick
by sliding housing on collective Check and adjust collective pitchstick friction
control interconnecting torque tube. Install bolts, using copilot collective pitch controls according
washers and nuts. Tighten nuts equally and by to instructions in Section 7, HMI Vol 1.
small increments until correct torque is applied
(Section 2, HMI Vol 1). 2-18. ELECTRICAL WIRINGAND SWITCHES
Electrical wiring and switches are duplicated
NOTE: On completing attachment of pilots on pilots and copilots collective pitch sticks.
collective pitch stick (step b) and inboard Refer to Section 19, HMI Vol 1 for repair of
collective stick assembly on collective con- switches and to wiring diagrams, Section 20,
trol interconnecting torque tube (step c), HMI Vol 1.
2-5/2-g
SECTION 3
3-1. GENERALINFORMATION. Installation of 3-5. REPLACEMENT OF FRICTION ADJUST

dual toany 369D helicop- CAM. The friction adjust cam in the pilots
ter equipped with optional dual controls (CSP-018). collective stick friction mechanism must be
Procedures as given the
approved methods to
are replaced with a washer (10, fig, 1-1). (See
be used when installing the dual starting kit and figure 2-1.)
are performed at owners and operators discre- a. Cut two nylon straps securing friction
tion. Reference is made in these instructions to mechanism guard to collective stick and remove
data in HMI Vol 1 and CSP-018 to accomplish guard.
installation of the dual starting kit. Ir Remove cotter pin, nut, retainer and
teflon and metal washers securing friction gear
3-2. REFERENCE DATA. Tables are used to to guide.
special tools (table 3-1), consumable
list c.Slide friction gear out, disengaging it
materials and expandable items (table 3-2). from idler gear. Remove friction gear and
Items listed in tables 3-1 and 3-2 are recom- friction adjustment cam from stick fitting.
mend.edby the manufacturer for use on Nughes d- Remove cam from gear assembly and
369D helicopters. All items listed in table 3-2 replace with washer (10, fig. 1-1).
are of a commercial nature and should be pro- e. Insert gear shaft through stick fitting and
cured locally. Alternate but equivalent items are guide. Ensure friction idler gear teeth mesh.
acceptable. _f. Reinstall washers, retainer and nut
removed in step 4. Install new cotter pin.
3-3. PREPARATION FOR INSTALLATION.
Refer to illustrated parts lists (Section I) before
installation to ensure that all required parts are NOTE: Do not install friction guard on pilots
included in the dual start kit. The list can collective stick until modification of pilots
also be used to identify any parts that may have collective stick is completed.
been damaged during shipment.
3-4. PILOTS COLLECTIVE PITCH STICK. 3-6. PILOTS COLLECTIVE PITCH STICK
The collective friction and throttle friction MODIFICATION. The stop release ring in the
mechanisms on the pilots collective pitch stick pilots collective stick must be replaced with a
must be deactivated when the dual start kit is Nylafil ring (12, fig. 1-1) and the throttle friction
installed. Modification of the friction nut must be drilled and locked in position by
mechanisms and stick assembly is required. pin (11).
Table 3-1. Special Tools
Item Part
No. Number Nomenclature Application or Use
1 369A9927 Collective rigging Rigging main rotor

fixture. collective controls.
2 369D29936 Collective bungee installation Molding collective bungee

tool. in compression.
3-1
Commercial Product(;Z)
Item
No. Material Specification No. (1) Name/No. Manufacturer
1 Grease MIL-G-2387 Bray Cote 627 Bray Oil Company

Aero Shell 7 Shell Oil Company
Exxon 5114EP Exxon Oil Company
2 Locking Compound MIL-S-22473 LOCKTITE No. 35 Loctite Inc.

705 No. Mountain Road
Grade A h/IIL-R-46082
Newington CT 06111
3 Solder, TinAlloy QQS-571 (3)

(C omp osition
SN60WRP2)
4 Nylon MIL-T-713 (3)
NOTES: (1) Numbers are Specifications and Standards. The prefix symbols are defined as
U. S. A.
Specification; Single, double or triple alpha prefix of the same letter Federal
AN Air ForcecNavy Aeronautical Standard; NAS National Aerospace
Standard.
the same type with the listed St3ecification No. cannot be determined.
a. Remove setscrews that secure switch Remove spring and idle stop release ring.
housing. e. Removegrip attach bolts. Slide throttle
grip, friction washer and discs, and friction nut
NOTE: Removal of additional setscrew is also from stick tube.
required on helicopters equipped with cargo Place throttle friction nut in suitable holding
release mechanism (C~t Eqpt Manual device and using 5/64- inch drill, drill hole fr om side
cPS-oos). figure 3-1.
to side of throttle friction nut as shown in
g. Using fish string attached to wire bundles

b. Cut nylon strap or twine that secures elec- during disassembly, feed wires through exit
tri~al wiring to stick tube. Push wire slack into hole at bottom of stick and pull them through
stick, carefully pull housing and wiring from end opening at top of stick.
of stick tube and disconnect wiring from switches. h. Install wire guide in stick tube with one
(For switch replacement, refer to Section 19, wire bundle in eath cutout. Align guide with
HMI Vol 1.) matching hole in stick tube and install setscrew.
c. Remove setscrew and wire guide from for- When tightened, setscrew must be at least flush
ward end of stick. Tie string on each wire bundle and not recessed more than 0. 010 inch below
to aid reassembly and remove wiring. outer surface of tube.
i. Using grease (1, table 3-2) lubricate ID of
NOTE: Idle step release ring will not be throttle grip and install grip on stick tube.
reinstalled at reassembly. Align grip and gas producer control tube fitting
3-2
.078-. 081
.250
.078-.081
.750
.078-.081
NOTE: ALL DIIV1ENS IONS

IN INCHES.
47-1150
Figure 3-1. Drilling Throttle Friction Nut Pilots Collective Pitch Stick
and install grip attach bolts. When tightened, 3-8. REPLACEMENT OF START SWITCH IN
bolts must be at least flush and not recessed COPILOT S COL LECTIVE PITCHSTICK~Bef ore
more than 0. 010 inch below outer surface of grip. installing copilots collective pitch stick 8, fig.
Establish end
play, add correct
zero 1-1), the installed start switch must be replaced
rotational friction (5-inch pounds maximum), then with the start switch (9) provided with the dual
match drill stick tube fitting threads to hole starting kit.
drilled in adjust nut. Install roll pin (11, fig. 1-1). a. Remove attaching hardware securing stick
Forward end of friction nut must not be more than grip switch housing. Remove housing and
0. 010 inch grom grip, switchplate.
4 Route wiring through ring (12) and spring, b. Disconnect installed start switch wiring and
Using solder (4, table 3-2) connect wiring to remove switch.
switches on switch housing. c. Connect wiring using solder (3, table 3-2)
I: Position ring and spring on grip and pull to start switch (9, fig. I-1).
slack from wiring in stick tube through exit hole d. Reinstall switchplate and housing and secure
at bottom of tube. Attach switch housing to grip housing to stick grip with attaching hardware.
swith setscrews.
m. Secure wiring to stick approximately one 3-9. REMOVAL OF COPILOTS COLLECTIVE
inch aft of exit hole, using nylon strap or twine STICK AND SOCKET.
(4, table 3-2). a.Remove copilots collective pitch stick
Place friction mechanism guard (removed
n. coverand collective pitch stick. (Refer to
in paragraph 3-5) on stick tube and secure with CSP-018.
two nylon straps.
WARNING: Install bungee installation tool
3-7. REPLACEMENT OF COPILOTS COLLEC- (2, table 3-1) before disconnecting any
TIVE PITCH STICKAND MBOARD COLLECTIVE collective stick hardware (either pilots or
PITCH STICK SOCKET. The copilots collective copilots). There is strong bungee spring
pitch stick and the inboard collective pitch stick pressure present in the stick linkage; if
socket must be removed and replaced with the suddenly released, spring reaction in the
new copilots collective pitch stick assembly linkage can cause personal injury, or parts
(8, fig. 1-1) provided. damage.
3-3
Sbctioli 3 Opt Eqpt Manual CSP-089
b. Remove inboard collectivepitch d. Align and/or match bellcrank centerline.

stick socket. (Refer to Section 7, HMI gearshaft assembly gear cutout and pilots
Vol i). throttle as shown in figure 3-3.
e. Position friction guide in seat structure
bracket with bushing (4, fig. 1-1), bushing (6),
3-10. INSTALLATION OF COPILOTS and three washers (5) loosely spaced between
COLLECTIVE PITCH bracket ears so guide is in line (parallel) with
a. Lubricate surfaces that are in contact stick. Install bolt (3), two washers (7), nut (2)
during rotation with grease (1, table 3-2) and new cotter pin (1).
Ifig. 3-2). f. Connect electricalplug.
b. Ensure that pilots and copilots throttle g. Perform operational check of collective
grips are in same relative positions. Slide stick friction and adjust friction mechanism as
copilots stick housing on collective intercon- necessary (Section 7, HMI Vol 1).
necting torque tube, align matching holes and h. Remove collective bungee installation tool.
secure stick to torque tube. (Refer to Section 7, HMI Vol 1.)
c, With pilots and copilots stick grips at Reinstall collective pitch stick cover and
mid-travel, rotate bellcrank back and forth other hardware removed for access.
slightly to engage socket assembly to gearshaft Move collective stick through full travel to
on hexagonal end of gas producer interconnect ensure there is no binding or interference from
torque tube. electrical wiring.
MOUNTING DISTANCE
SHIM (CUT)
BEARING
(NOTE 2) COPILOTS COLLECTIVE
STICKHOUSING
GAS PRODUCER
CONTROL TUBE C
NOTES:
PINION
FITTING
INOTE 1)
alt
i. SURFACES IN CONTACT DURING ROTATION TO BE
LUBRICATED WITH GREASE (1, TABLE 3-2).
2. INSTALL WITH GRADE A LOCKING COMPOUND

12, TABLE 3-2) AFTER SHIMMING FOR MOUNTING
DISTANCE AND BACKLASH.
BEARING
INOTE 2)
BACKLASH
SHIM
GEAR SHAFT
i
71)- ASSEMBLY
SH
SHIM
BEARING
47-1151
(NOTE 2)
Figure 3-2. Gas Producer Control Tube Exploded View
3-4
CSP-089 Opt Eqpe Manual Section 3
0. 699-0. 709 IN.~ ~t- PINION GEAR

MOUNTING
HOUSING~ t~l I IMrlDISTANCE
STEP 4
FWD
STEP 2
STEP
STEP 1
jJII II LINK
BELLCRANK
TOP VIEW
IDLE STOP
N1CLDSED--L
GE_NERAL NOTI: CR I P M I D -TRA VEL
SELECT SHIM STOCK AS RE9U IAED.
CRES SHIMS PROVIDED IN 0, 002-,
,r
I N1OPEN
0. 005-, 0.012;, AND D. 032- IN.- THICKNESSES, )j
15
i 71"30
:15"
t 70"40
CENTERLINE OF STICK
AND GEARSHAFT GEAR
u
CUTOUT
2"50
GAS PRODUCER
RIGHT SIDE VIEW CONTROL TUBE
STEP 5
II~ INSTALL MOUNTING D ISTANCE SH IMS FOR 0. 699-0, 709 IN. STEP 4: IN STALL BACKLASH SH IMS TO OBTAIN D. 003 IN.
PINION GEAR MOUNTING DISTANCE. AFTER SH[MMING 15 MAXIMUM BACKLASH
CORRECT, INSTALL BEARING IN HOUS ING WITH GRADE A CAUTION: HOUSING AND CAP BEARINGS MUST BE
LOCK ING COMPOUND 12, TABLE 3-2), SEATED AGAINST BORE SHOULDER, GEARS
NOTE: SHIMS ARE CUT THROUGH ONE EDGE FOR MUST NOT BIND. AND PINION MOUNTING
INSTALLATION. D I S TANCE MUS T B E COR RECT.
STEP 2: APPLY 10 LB MINIMUM LOAD TO END OF PINION DURING STEP 5: AFTER SH(MMING IS CORRECT, INSTALL GEARSHAFT
CHECK OF MOUNT ING D ISTANCE D IMENS ION. BEARINGS W ITH GRADE A LOCKING COM POUND.
NOTE: TIGHTENING THROTTLE FRICTION NUI APPLIES INSTALL GEARSHAFT IWITH LINK ATTACHED TO
SUFFICIENT LOAD. BELLCRANK) SO THAT .POSITION OF BELLCRANK, AND
CENTERLINE OF GEARSHAFT GEAR CUTOUT ARE AS SHOWN,
STEP 3: POSITION THROTT~E GRI P AT MID-TRAVEL. CENTERLINE OF CEARSHAFT CUTOUT SHOULD MATCH
NOTE: ONE PINION GEAR TOOTH EQ(IALS 5"38. CENTERLINE aF STICK,
NOTE: CENTERLINE OF GEARSHAFT GEAR CENTER
TOOTH IS 2"50 OFF THE CUTOUT CENTERLINE. 47-1152
Figure 3-3, Adjustment of Cas Producer Drive Mounting Distance and

Backlash Copilots Collective Stick
3-5/3-6
CSP
094
Publication No. CSP -094
Illustrafed Parts list

and
with Initial Installation instructions
FOR
ENGINE AIR INLET DIVERTER KIT
PART NO. 369D292044, -501

PART NO. 369D292045
USED ON HUGHES MODEL 500D/E (369D/E) HELICOPTERS
DO NOT DESTROY MANUAL. REPLACE

LIKE-NUMBERED PAGES WITH
THESE DATED PAGES.
Hughes Helicopters, Inc. Culver City. Calif ornia 90230

COD831103 Issued 15 August 1983

Revised 15 July 1985
IVI FG I
INTRO
Opt Eqpt Manual
INIEIT L*IEST CHINCED P*CES. DLJTIOI SUPt~SEDCO PAtIS.

1IST OF EFFECTIVE PAGES
Page Issue
Title 15 Jul 85
"A 15 Jul 85
B Original
CBlank Original
*i 15 Jul 85
ii Blank Original
F-l Original
1"-2 Blank Original
*I-lthru 1-5 15 Jul 85
1-6 Orirrinal
1-7 15J~j 85
2-1 Original
3-1 Original
3-2 15 Jul 85
*3-6 15 Jul 85
A Revised 15 July 1985

HUGHES HELICOPTERS, TNC. TECHNICAL MANUAL RECOMMENDED CHANGE REPORT
Publications Department and

This manual has been prepared and distributed by the Commercial Service
is intended for use bypersonnel responsible for the maintenance of Hughes Helicopters. Periodic
reader, any information has been omitted or requires clarification, please
direct your comments to this
revisions.
Hughes Helicopters, Inc.l


6A141
Originator
Address
Volume Title
Helicopter Model
Revision Date
Discrepant Area las applicable):
Figure Number(s)
B/C
RECORD OF REVISIONS
CSP-094
MFG REV
DESCRIPTION ISSUEDATE ATP REVDATEI INSERTEDBY
NO
7/15/85 2/27/86 ATP/KK
CSP-094 Reissue

1^
Table of Contents
01,1 El11,1 Fui:lnu;ll
CSP-094
TABLE OF CONTENTS
Section
FOREWORD F-l
F-l. Purpose ;Llld Content

of this Manual F-l
F-5, Compatibility of
Combined Optional
Equipn~ent F-l
F-7, Organization of
Contents F-l
F-9, Use of this Manual F-l
F-~l. Related Publications F-l
F-13, Literature Changes and
Revisions F-l
1 ILLUSTRATED PARTS LIST
1-1, Scope and Contents...... 1-1

1-3. Group Assenlbly
Parts List 1-1
Usa~e on Code 1-1
i/ii
CSP-094 rable nl Contents
TABLE OF CONTENTS
Scclic,ii page
2 INSTRUCTIONS.. 2-1
2-1. General I~lformation..... 2-1

2-3. Maintenance of Engil~e
Air Inlet Diverter 2-1
3 INSTAI,I,ATION INSTRUCTIONS.. 3-1
3-1. General Illformation..... 3-1

3-2. Scope 3-1
Installation 3-1
3-5. nemoval of Engine Air
Illlet Fairings 3-1
3-6. nemovnl of Engine
Fairing Supports 3-1
3-7. Installation of Engine Air
Illlet Diverter Fairings 3-1
3-8. Installation of Plexiglass
Stiffeners to Upper
Cnnopy Windshield 3-6
3-9. Weight and Balance Data 3-6

i /ii
~ORMIORD
tained in the Basic Handbook of Maintenance these are presented in sequence as defined in
Instructions (HMI Vol 1) and the Illustrated Section i, HMI Vol 1.
Parts Catalog (369D/E-IPC), and contains instruc-
tions for initial installation and continuing main-
tenance for the engine air inlet diverter. Weiffht
and balance data is included. This manual also
contains parts lists for procuring replacement F-10. This manual is for use by operators of
parts for the engine air inlet diverter the model 500D/E helicopter equipped with a
engine air inlet diverter. Although this manual

F-3. APPLICABILITY. is a separate publication, it should be kept with
HMI Vol i, HMI Vo12, 369D/E IPC and other
F-4. The engine air inlet diverter is applicable handbooks listed in Section 1, HMI Vol 1 that
for use on any Hughes Model 500D/E (369D/E)
form the primary information file for the
helicopter. Part No. 369D292044 and 369D292044- helicopter.
501 have been superseded by 369D292045. For
replacement of 369D292044, -501order
369D292045,
F-5. COMPATIBILITY OF COMBINED F-12. Reference is made to applicable portions

OPTIONAL of HMI Vol 1, 369D/E IPC and applicable Opt
Eqpt Manuals as required to accomplish instruc-
F-6. For compatibility information on which tions contained herein.
combination at the same time, refer to Section 21,
HMI- Vol i.

F-8. The contents of this manual are grouped manual are made as defined in Section i,
into sections as outlined in the Table of Contents. HMI Vol i.
F-1/F-2
SECTION 1
1-1. SCOPE AND CONTENTS. purpose. For information or procurement of other

replacement parts, refer to the 369D/E IPC.
means of text (parts lists)
and companion illus- 1-5. ILLUSTRATIONS.
trations, complete parts definition of the engine
a
air inlet diverter kit configuration, manufactured 1-6. Isometric illustrations are provided for
by Hughes Helicopters, Inc,, Culver City, each group assembly parts list. Each illustra-
California. tion is exploded to the extent necessary to show
parts relationship for the engine air inlet diverter.
NOTE
The illustrated parts list is organized and

1-8. The USABLE ON CODE column located at
presented in the same manner as the 369DiE
the right-hand side of the Group Assembly Parts
Series Illustrated Parts Catalog (369D/E
List pages indicates the effectivity of parts by
IPC). (For information on use, refer to
aircraft serialnumber. In many cases two
369D/E -IPC.)
different parts are representing the
listed, one

1-4. Theparts list furnish information for pro- applications of a given part. When no USABLE
curing replacement parts for the engine air inlet ON CODE is listed, items are understood to
diverter and shall not be used for any other have full effectivity.
1-1
Section 1 ~pt Eql?t Manual CSP-094
O
11
e
B
.w
7
1
e k
47-1165
Figure 1-1. Engine Air inlet Diverter 5991)
132 Revised 15 July 1985

Section 1
UNITS USABLE
FIG.
DESCRIPTION PER ON
INDEX PART
ASSY CODE
NO. NO.
369D292044 ENGINE AIR ~LET DIVERTER 1

1-1-
(For replacement order 369D292045
see figure 1-3.
72
-1 NAS1738B4-3 I. RIVET.
4
-2 NASG 2 3 -3 -3 1. SCREW
WASHER 4
-3 AN960PD10L
RISrET 10
-4 MS20426AD3
4
-5 NAS698A3 I. NUTPLATE
NUTPLATE 5
-6 NAS697A3 i.
FLANGE ASSY, LH................. 1
-7 369D2044-35 1
369D2044-36 FLANGE ASSY, RH I 1
FAIRING ASSY, LH 1
-8 1 369D292044-1
FAIRING ASSY, RH 1
369D292044-2
-9 1 369D292579-3 1. CARD, VNE.... 1
3692)292579-5 1. CARD, 1
369D292579-7 CARD, VNE 1
-10 369D22070-50 1 BLOWER ACCESS DOOR 1
-11 36 9D2405 -29 PLEXIGLASS STIFFENER 1
-12 369D2405-30 1 PLEXIGLASS STIFFENER 1
1-3
CSP-094
i i 11~ 10
ii C/ Y
12
Q
11~
:;?C
It
Ba~.,
O
i B
7
1o ;0 -a3
~8- _
-g
47-1163
Figure 1-2. Engine Air Inlet Diverter 500E
Revised 15 Jutg 1985

1-4
UNITS USABLE
FIG.
DESCRIPTION PER ON
INDEX PART
ASSY CODE
NO. NO.
1-2- 369D2 92044 -501 ENGINE AIR INLET DIVERTER 1
(For replacement order 369D292045,

see figure 1-3)
RIVET 72
-1 NAS1738B4-3
SCREW 4
-2 S623-3-3 1
WASHER. 4
-3 960PD10L
RNE T 10
-4 MS20426AD3
4
-5 NAS698A3 I NUTPLATE
I NUTPLATE 5
-6 NAS697A3
LH 1
-7 369D2044-35 FLANGE ASSY,
FLANGE ASSY, RH 1
369D2044-36
FAIRING ASSY, LH. 1
-8 1369D292044-41
FAIRING ASSY, RH 1
369D292044-42
1369D292582-3 CARD, VNE 1
-9
369D292582-5 CARD, VNE 1
369D292582-7 CARD, VNE 1
369D22070-501 1 BLOWERACCESS DOOR 1

-10
369D2405-29 1 PLEXIGLASS STIFFENER 1
-11
369D2405-30 1 PLEXIGLASS STIFFENER 1
-12
1-5
o i
E
4
e
ol e,
to
~I
7
1iis
11 ._ b) O
"u,
2
U4. ~t
47-1182
Figure 1-3. Engine Air Inlet Diverter. 500D/E (369D292045)
1-6
FIG. UNITS USABLE

NO. NO. ASSY CODE
1-3- 369D292045 ENGINE AIR INLET DIVERTER ASSY 1

(369D292045 supersedes 369D292044
and 369D292044-501)
-1 369D2 92045 -15 SUPPORT I 1
-2 369D2 92045 -16 1 SUPPORT I 1
-3 MS20470AD3 I RIVET A/R
-4 NAS1097 I RI\VET 8
-5 NAS623-3-6 I SCREW 1 6
-6 NAS623-3-3 I SCREW 1 4
-7 AN960PD10L I WASHER 1 4
369D292045-11 PLATE ASSY 2
-8 MS210i2-LK3 I NUTPLATE 1 4
-9 369D292045-13 1 PLATE 1 2
369D292045-3 FAIRING ASSY 1
-10 369D292045-5 1 SKIN I 1
-11 369D2 92045 -7 1 FLANGE I 1
-12 369D292045-9 1 LI~P 1
369D2405-29 PLEXIGLASSSTIFFENER I 1
(Refer to item 11, fig. 1-2.)
3691)2405-30 1 PLEXIGLASSSTIFFENER I 1
(Refer to item 12, fig. 1-2.
Revised 15 July 1985 1-7/1-8

SECTION 2
IVIAINTENANCE INSTRUCTIONS
2-1. GENERAL INFORMATION. establishes the main air inlet duct which directs
ambient outside air to the engine inlet, oil cooler
2-2. DESCRIPTION. A Hughes Model 500D/E blower, and main transmission. It also reduces
(369D/E) helicopter may be equipped with an ingestion of large dust and sand particles, as well
engine air inlet diverter, instead of the standard as snow and slush, which may accumulate on the
engine air inlet fairings (Section 3, HMZ Vol 1). canopy at low speeds and subsequently swept
The engine air inlet diverter is fabricated of toward the air inlet when forward speed is
glass cloth layers over polyurethane foam fillers. increased.
The engine air inlet diverter completely encircles
the mast support structure, which reduces the
ingestion of foreign obiects into the engine air 2-3. MAINTENANCE OF THE ENGINE AIR
inlet which might be of sufficient mass to punc- INLET DIVERTER. Maintenance of the engine
ture the screen particle separator and damage air inlet diverter is similar to that of standard
the engine. The engine air inlet diverter
engine air inlet fairing (Section 3, HMI Vol i).
2-1/2-2
SECTION 3
3-7. ~STALLATION OF ENGINE AIR INLET
3-1. GENERAI, INFORMATION.
3-2. SCOPE. Procedures in this section may be

performed at the operators discretion and are NOTE
applicable to all 369D/E helicopters. These
instructions provide for the installation of the
air inlet diverter kit.
On helicopters utilizing PN 369D292045,
engine
proceed to step q.
3-3. REFERENCE DATA. Table 3-1liststools
and equipment. Consumable materials and a. On helicopters utilzing PN 369D292044,
expendable items are listed in Table 3-2. Items -501, set new left and right fairings in final
listed in the tables are recommended by the assembly position. Attach them to engine
manufacture for use in Hughes Model 500D/E aft section inlet fairing with one screw at top
Series helicopter. center. (See fig. 3-1 for 500D and fig. 3-2
for 500E.
3-4. PREPARATION FORINSTALLATION, Pre-
paration for installation of the engine air inlet
diverter kit includes the following: NOTE
a. Ensure all electrical switch~s

are set to PN 3690292044-15/16 Closures (components
OFF. Ensure that BATTERY-OFF-EXT switch of PN 369D292044 Fairing Assembly) may
is OFF. require trimming to clear mast and control;
trim as required. (See fig. 3-lfor 500D
b. Identify all components, including attaching and fig. 3-2 for 500E.
hardware, to be removed for access to work
areas. Protect components from damage and
b. Install two screws through left and
foreign matter until reinstalled.
right fairings along rear top center and two
3-5. REMOVAL OF ENGINE AIR ~LET inside, also install four screws through over-
FA lapping front vertical edges of left and right
fairings.
a. Remove inspection access door from exist- Set left and
right flange assemblies against
ingright inlet fairing assembly. base of fairings in final assembly position, and
verify that flanges are in proper contact with each
b. Remove existing engine left and right inlet other at front end, then tape flanges to fairings
fairing assemblies by removing 16 screws secur- and to fuselage.
ing fairing flanges, 14 screws joining aft section
engine inlet fairing, and 2 screws joining left and d. 1/18-inch drill bit into front pilot
Insert
right fairings inside. hoi~es flanges and drill holes in fairings, then
in
installblack, 1/16-inch Wedgelock (or similar)
NOTE fasteners in holes, readjust flanges to proper
position as required, then drill through remaining
Identify and retain all components, including pilot holes, each side. Install fasteners in
hardware, removed from helicopter, approximately every other pilot hole.
e. Remove fairings from helicopter, and

3-6. REMOVAL OF ENGINE FAIRING SUPPORTS.
enlarge pilot holes in fairings to 0. 128 inch for
(369DZ92045-ONLY)
1/8 inch rivets. Use No. 30 drill.
a. Remove existing 369D22400-3 and -4 Install NAS1738B4-3 rivets in flange to

supports and attaching hardware by removing fairing holes, with Cherry 350 gun and 35004 nose
rivets and nutplates. (See fig. 3-3.) assembly, or equivalent.
3-1
Table 3-1. Tools and Equipment
Item
No. Part Number Nomenclature Manufacturer
1 AT550M (46) WeBgelock Fastener Wedgelock Division,

MonogramIndustriesj Inc.
1001 Monterey Pass Road
Monterey Park, CA 91754
2 200 Pliers Wedgelock
3 AT532-65 or AT500-55 No. 10 Hole Finder ATIIndustries, Inc.

220 N. Tulip Street
Escondido, CA 92025
4 350 Rivet Gun Cherry Fasteners, Townsend

Div. of Textron, Inc.
1224 E. Warner Avenue
Santa Ana, CA 92707
5 35004 Nose Assy Cherry Fasteners
6 Drill Motor, Comm erc ial
Portable 1/4 inch
7 Drill Bits: Commercial

1/16 inch
No. 30 (0. 128 inch)
No. 9 (0. 1960 inch)
No. 7 (0.2010 inch)
Specification Commercial Product(a)

Item Material
(1)
No. Name/No. Manufacturer
1 Primer coating, zlinc 908-L-02110 Glidden-Durkee Div., SCM Corp.

chromate, Low-moisture- 900 Union Commerce Building
sensitive (Federal Spec Cleveland, OHIO 44115
TT-P-1757)
2 Acrylic Lacquer 1063-166 E.I. DuPont de Nemours and Co.

Marshall Laboratory
3500 Grays Ferry Avenue
Philadelphia, PA 19146
3 Acrylic Cement, Type m, MIL-A-8576 Commercial
Non-Solvent, Medium
Viscosity
NOTES: (1) Numbers are U. S. A. Specifications and Standards. The prefix symbols are defined as
Specification; Single, double or triple alpha prefix of the same letter Federal
Specification; AN -Air Force- NavyAeronautical Standard; NAS National Aerospace
Standard.
3-2
Revised 15 ~uly 1985
9
-i i 3
NUTPLATE 3
6; TEVIRDQREQD
6 ER
NUTPLATE 2 RE
RIVET 4 REPD
CLOSURE
TRIM AS REQUIRED
FAIRING ASSY, R,H.
o~ e
WASHER.
a o~-
8 -a
6, -~o
o
Q_
FLANGE ASSY, R.H. ~-;;oOO

o a
o
RIVET OO,oo oo os o_o_oo_
FAIRING ASSY, L.H.
a
FLANGE ASSY, L.H.
47-1166
Figure 3-1. Engine Air Inlet Diverter Kit for 500D Helicopter
3-3
C-_
Y/
i/
9
NUTPLATE 3 REQD
RIVET 6 RE9D
NUTPLATE 2 REQD
RIVET 4 REQD
CLOSURE
TRIM AS REQUIRED
FAIRING ASSY. R.H
WASHER
SCREW
oo
bo_
P"~.
oOO
ov
FLANGE ASSY, R.H.-
FAIRING ASSY, L.H.
RIVET FLANGE ASSY, L.H.
47-1164
Figure 3-2. Engine Air Inlet Diverter Kit for 500E Helicopter
3-4
NUTPLATE 2 REPD
RIVET 4 REIID
(TYP 2 FL.)
iC
(TYPPCATE2 FL.)
CLOSVRE TRliv\
AS RWUIRED
FLANGE ASSY
SCREW
I~
WASHER SCREW
47-1183
Figure 3-3. Engine Air Inlet Diverter Kit for 500D/E. (369D292045)
3-5
NOTE NOTE
Before installing rivets, deburr holes as For helicopters utilizing PN 369D292045,

required, and coat holes in aluminum flanges refer to fig. 3-3 when performing the
with 908-L-02110 primer coating, or equiva- following steps.
lent. Install rivets while coating is wet.
q. Positionsupports (1, 2, fig. 1-3) into
g. Reinstall fairing assemblies, and secure place td mark points for any required new drill-
with screws as before (para 3-7).
ing. (Use as many existing attach points as
possible.) Using No. 7 drill bit, locate and
NOTE drill required new holes.
Beforedrilling pilot holes in flanges, Install rivets and nutplates for
r. as required
remove interior paneling from ceiling so each support.
frequent checks of accuracy can be made.
Cover lower interior of helicopter with drop s. Position fairing assembly (11, fig. 1-3)
cloth to catch metal chips. into place. Locate hole locations for the installa-
tion of the plate assemblies (8, fig. 1-3) which
h. 10 hole bo"ds the fairing assembly to the existing engine
Using a No.finder, locate and drill
heres in new left and right flanges assemblies, fairing.
Remove hole finder and enlarge holes, using t. Using a No. 7 drillbit, drill required holes
No. 7 (0. 2010 inch) drill. into both fairing assemblies.
i. Remove fairing assemblies from helicopter, u. Install screws (6, fig. 1-3) and washers
an~d install nutplates for access door. (See fig-
ures I-lfor 500D and 1-2 for 500E.)
v. Using a No. 7 drillbit, locate and drill
Apply primer coating inside holes in flange holes through flange (13, fig. 1-3). Install
assemblies, then allow primer to dry thoroughly. screws (5, fig. 1-3) into flange securing the
After coating has dried, apply top coats of
fairing assembly (11, fig. 1-3).
acrylic lacquer to match original pattern.
3-8. INSTALLATION OF PLEXIGLASS STIFF-
k. Install fairing assemblies, then install ENERS TO UPPER CANOPY WINDSHIELD.
access door.
a. Trim 0. 75 inch from outboard end of each
i. Remove drop cloth, and vacuum interior stiTfener.
b. Prepare acrylic cement per manufacturers
m. Reinstall ceiling paneling. instructions.
n. If ship is equipped with PN 369D22070-BSC c. Apply cement per manufacturers instruc-
blower access door assembly, remove and tions to stiffeners and canopy and install stiff-
replace with PN 3691)22070-501 blower access eners as shown in figure 1-2. (Approximately
door assembly. 6.0 inches forward of station 89. 39 on the
interior surface of the canopy.
Replace PN 369D26531-35, -37, -39 and/
o.
or369D26531-29, -31, -33 V,, cards with 3-9. WEIGHT AND BALANCE DATA.
PN 369D292579-3, -5, -7 V,ecards for 500D
helicopter. 3-10. Weight and balance data resulting from
installation of engine air inlet diverter kit is
p. Replace PN 369D292579-3, -5, -7, V,, listed in Table 3-3. After installation of kit,
cards with PN 369D292582-3, -5, -7, V, incorporate changes in helicopter weights and
cards for 500E helicopter. balance records as instructed in HMI -Vol 2.
Table 3-3. Weight and Balance Data
Weight Arm Moment

(Pounds) (Inches) tin. -lb/100)
Added 11.52 92.8 1.41
Removed -0. 02 90. 4 -0. 02
Change +1.50 92,7 +1.39
3-6 Revised 15 1985

July
CSP
100
Opt Eqpt Manual Publication No. CSP-100

and
with Ilritial Ins2allation Instructions
FOR
250-C20R/2 ENGINE CONVERSION INSTALLATION KIT
Part No. 36913298000-519 and -523
USED ON MDHC 500D and 500E (MODELS 369D and 3693) HELICOPTERS
~1


5000 East McDowell Road
Mesa AZ 85205-9797
Revised 6 April 1990

Issued 15 November 1989
nn FG I
INTRO
INSERT LATEST CHANGED PAGES, DESTROY SUPERSEDED PAGES

LIST OF EFFECTIVE PAGES
The Asterisk Indicates Pages Changed, Added, or Deleted by
the Current Change
Date of issue for original and change pages are:
CSP-100 has been revised in its entirety;

Original......... 6 April 1990
Title ..........Original iii/(iv blank) ....Original

A/(B blank). ....Original F-1/(F-2 blank) ..Original
C/(D blank) ....Original 1-1 thru 1-11/(1-12 blank)............. Original
i/(ii blank) ......Original 2-1 thru 2-25/(2-26 blank) .Original
A/(B blank)
MCDONNELL DOUGLAS HELICOPTER COMPANY

TECHNICAL MANUAL RECOMMENDED CHANGE REPORT
This manual been prepared and distributed by the Technical Publications Department and is
has
intended for by personnel responsible for the maintenance of MDHC Helicopters. Periodic revision
use
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.

5000 E. McDowell Road
Mesa, AZ 85205
Attention: Technical Publications, Light Helicopter

548/ D214
O riginator
Address
Issue Revision No.

Date
Figure Number(s)
Remarks/Recommendations:
C/(D blank)
RECORD OF REVISI~NS
~a CSP-1 00
MFG REV

TABLE OF CONTENTS
Section Page Section Page
FOREWORD.......... F-l 2-8. Modifications 2-5

F-l. Purpose and Contents 2-9. Instrument Panel 2-5
of This Manual F-l
2-10. Anti ice Cable System
F-2. Applicability F-l Removal (250-C20B) 2-5
F-3. Organization of Contents F-l 2-11. Inlet Doubler
Assembly
F-4. Use of This Manual F-l Installation 2-6
F-5. Related Publications F-l 2-12. Engine Oil Tank

F-6. Literature Changes and Removal (250-C20B) 2-6
Revisions F-l 2-13. Oil Tank
Engine
Installation (250-C20R/2)... 2-6
ILLUSTRATED PARTS LIST 1-1 2-14. Modifications
Wiring 2-6
i-I. Scope and Events 1-1 2-15. Electrical Wiring Replacement 2-6
1-2. Group Assembly Parts List 1-1
2-16. Anti ice System
1-3. Illustrations .........1-1 Modification ........2-18
1-4. Usable on Code 1-1 2-17. Auto Re-ignition Modification
(3691) helicopter only) 2-21
MAINTENANCE INSTRUCTIONS 2-1 2-18. Scavenge Oil Filter
2-1. General Information 2-1 Installation 2-21
2-2. Reference Data 2-1 2-19. Engine Installation and

2-3. Description....... 2-1 Alignment (250-C20R/ 2) 2-21
2-4. Troubleshooting 2-5 2-20. Engine Rigging and
2-5. Preparation .........2-5 Adjustment (250-C20R/2) 2-21
2-6. Removal of 2-21. Engine Operational

Helicopter
Equipment 2-5 Check (250-C20R/2)..... 2-21
2-7. Electrical Bonding Connections 2-5 2-22. Weight and Balance 2-21
ii (ii blank)
LIST OF ILLUSTRATIONS
Figure Page Figure Page
1-1. 250-C20R/2 Engine Installation 2-4. Component Locations and Wire

Kit............l-2 Routing Installation..... 2-10
1-2. 250-C20R/2 Engine Installation 2-5. 250-C20R/2 Wiring Diagram 2-15
Kit 1-4 2-6. Battery (K310) and External

Power (K309) Relay -Initial
1-3. 250-C20R/2 Engine Installation
Installation (369D Helicopters
Kit 1-7
Serial Nos. 003-723)..... 2-17
1-4. 250-C20R/2 Engine Installation 2-7. Anti ice System Modification
Kit 1-9 Instrument Panel 2-20
2-1. Interchangeable Engine Buildup 2-8. Auto Re-ignition System

Modification Component
Components 250-C20B and
250-C20R/2 2-2 Locations (Effective 369D
Helicopters Only) 2-22
2-2. PanelDecal
2-9. Auto Re-ignition Modification
Applications -250-C20R/2... 2-7
Wiring Diagram (369D
2-3. Inlet Assembly Doubler Helicopters Only) 2-23
Installation 2-8 2-10. Oil System Hose Removal 2-26
iiil (iv blank)

Opt Eqpt Manual Publication No. CSP-100
FOREWORD
F-l. PURPOSE AND CONTENTS OF THIS F-3. ORGANIZATION OF CONTENTS.
MANUAL. The contents of this manual are grouped into
This manual supplements information contained sections as outlined in the Table of Contents.
in the HMI and 369D and 369EIFF (CSP-D4 Each section is organized to provide comprehen-
sive coverage of the systems, major equipment
and CSP-EIF-4) IPC. It contains instructions for
Allison 250-C20B with groupings, and major components that are simi-
converting engines
lar or associated. Procedures for each of these
250-C20R12 engines, and continuing maintenance
are presented in sequence as defined in ~ntroduc-
for 3691)298000-519 (36913) and 369D298000-523
tion (HMI).
(3683) 250-C20R/2 engine. Parts lists are in-
cluded for use in procuring replacement parts for F-4. USE OF THIS MANUAL.
the system. This manual is for use by operators of the
MDHC 500 (Models 3691) and 3693) helicopter.
F-2. APPLICABILITY. Although this manual is a separate publication,
it should be kept with HMI and other
NOTE handbooks listed in Introduction (HMI) that
form the primary information file for the heli-
Engine and battery are customer supplied
and included in The copter.
not package. 250-
C20R/2 engine requires 17 amp hr battery
F-5. RELATED PUBLICATIONS
(369D290011). If not installed, refer to Reference is made to of HMI
applicable portions
CSP-093 for installation instructions. and 369D and 3693/369F Illustrated Parts Cata-
log IPC (CSP-D-( and CSP-EIF-8), applicable
Opt Eqpt Manuals and Allison Operation and
The Allison 250-C20R/2 engine is applicable for Maintenance manual publications as required to
use on MDHC 500 (Models 369D and 369E) heli- accomplish instructions contained herein.
copters. For compatibility information on which
optional equipment may or may not be used in F-6. LITERATURE CHANGES AND
combination at the same time, refer to Section REVISIONS.
Changes and revisions to contents of this manual
IX, of appropriate Pilots Flight Manual.
are made as defined in Introduction (HMI).
F-1/(F-2 blank)
SECTION 1
1-1. SCOPE AND EVENTS. 1-3. ILLUSTRATIONS.
This illustrated parts list provides, by means of Isometric illustrations are provided for the group
text (parts list) and companion illustrations, a assembly parts list. The illustrations are exploded
definition of parts of the 369D298000-519 and to the extent necessary to show parts relation-
3691)298000-523 conversion 250-C20R/2 engine ship for the 250-C20R/2 engine installation.
conversion installation manufactured by MDHC,

Mesa, Arizona.
The USABLE ON CODE column located at the
NOTE right-hand side of the Group Assembly Parts

List pages indicate the effectivity of parts by air-
The illustrated parts list is organized and craft model. In many cases, two different parts
presented in the same manner as the 369D are listed, one representing the original installa-
and 3693/369F Illustrated Parts Catalog tion and another representing an improved re-
IPC (CSP-D-I and CSP-E/F-4). For infor- placement Alphabetic codes are used to in-
item.
mation refer to the 369D and dicate the aircraft model application of a given
on use,
3693/369B IPC (CSP-D-4 and CSP-E/F- part. The alphabetic codes used in this manual
are listed and explained below:
4).
1-2. GROUP ASSEMBLY PARTS LIST.

The parts list furnish parts list information for USABLE ON CODE AIRCRAFT
250-C20R/2 engine installation and shall not be LETTER MODEL
used for any other purpose. If part numbers in
A 389D
this manual conflict with those listed in the
IPC (CSP-D-4, CSP-EIF- B 3693
369D or 36931369F
4), those listed herein should be used.
1-1
C~P-.
I
s 2
7 3
s 4
XB~\
14
i2
YLL~
/b,
57-149-3
Figure 1-1. 250-C20R/2 Engine Installation Kit
1-2
Section 1
UNITS USABLE
FIG.
PART DESCRIPTION PER ON
INDW
NO. NO. ASSY CODE
1-1- 369D298000-519 KIT, 250-C20R/2 ENGINE INSTALLATION

(Customer Supplied Engine and Battery) 1 A
369D298000-523 KIT, 250-C20R/2 ENGINE INSTALLATION

(Customer Supplied Engine and Battery) 1 B
-1IMS21043-08 NUT a B
-2 1 NAS1352C08-8 BOLT 6 A/B

-3 1 NAS620C08L WASHER 12 AB
-4 1 369D28750-501 SEAL PLATE 1 AV B

Alternate
369D28750-503
-5 1 369D28749-11 BELL, AIR INLET 1 A/B
-6 1 369D28410 REDUCER 1 A/B
-7 1 393-003 SNUBBER 1 A/B
-8 NAS617-4 .PACKING 3 A/B
-9 1 NAS617-8 PACKING 2 A/B
-10 NAS617-10 .PACKING 2 A/B
-11 NAS617-12 PACKING I A/B
-12 MS9135-1 .GASKET 1 AIB
-13 MS29512-03 .PACKING 1 A/B
-14 MS29512-04 .PACKING 1 A/B
NOTE
Used with new engine air bleed air valve.
1-3
V
(D
18
Q "Y~
io
P/
w
Ij !I
57-149-1A
Figure 1-2. 250-C20R/2 Engine Installation Kit (Sheet I of 2)
1-4
5 ~b,,,,,
3
~3J2
O2
O 3
15
12 (D
)I
I\-\
(I
CQ, (D
11
12YI
12
O
L
O 57-149-2A
Figure 1-2. 250-C20R12 Engine Installation Kit (Sheet 2 of 2)
1-5
FIG. UNITS USABLE

NO. NO. ASSY CODE
1-2- 3691)298000-519 KIT, 250-C20R/2 ENGINE INSTALLATION

(Customer Supplied Engine and Battery) ..........I 1 A
369D298000-523 KIT, 250-C20R/2 ENGINE INSTALLATION
(Customer Supplied Engine and Battery) ..........I 1 B
-1 NAS1303-1 BOLT .1 3 A/B

-2 MS21042-3 .NUT ....................................I
3 A/B
-3 1 AN960C10L WASHER ..............1 10 A/B
-4 1 MS21919WCH3 I CLAMP 1 2 A/B
-5 1 MS21919WCH8 CLAMP 1 2 A/B
-6 10904 CLAMP ..................................I
1 A/B
Alternate
MS9825-02
-7 6843332-03 .PACKING .............1 2 B
-8 MS9134-1 .GASKET ..............1 2 A
-9 1 NAS617-3 PACKING 1 2 A/B
-10 57D2-001 .SNUBBER ................................I
1 A/B
-11 MS29512-02 PACKING I 1 A/B
-12 MS29512-03 .PACKING .............1 3 A/B
-13 MS29512-05 .PACKING I 1 A/B
-14 369D28748-501 .HOSE ASSY (BLEED AIR) 1 A/B
-15 3691)28405 .GASKET ..............I 1 A/B
-16 M85049/60- .BACKSHELL ..............................I
1 A/B
2G08N
-17 M83723/75R08036 .CONNECTOR .............................I
1 A/B
-18 HS3190B8 .GASKET ..............1 2 A/B
1-6
6 O O
0000~00C000000
I~ V;7~\I/ p,
C 9
o
Ib
I
12 IS 6
oo
e i ii sa
ol 08
oo
[t~il
a 8
V~lo o Q
o
I -i
o 000
I :1 13
4/ 1 1 12
O 47-1300A
Figure 1-3. 250-C20R/2 Engine Installation Kit

1-7
FIG. 8 UNITS USABLE

INDEX I PART DESCRIPTION PER ON
NO. NO. ASSY CODE

(Customer Supplied Engine and Battery) ..........I 1 A
369D298000-523 KIT, 250-C20R/2 INSTALLATION
(Customer Supplied Engine and Battery) ..........I 1 B
-11369A8301-507 TANK, OIL ............I 1 A

-2 1 NAS617-8 PACKING .............I 1 A/B
-3 NAS617-10 PACKING .............I 1 A/B
-4 1 1741050-01 SCAVENGER OIL FILTER ASSY .............I 1 A/B
-5 1 369D26546-BSC .VNE CARD (Set) ...........................I
1 A
-6 1389114526-19 INDICATOR, TORBUE 1 Al B
-7 1 369A4521-11 INDICATOR, TOT .......I 1 A/B
-8 1 369D296305-23 INSTRUMENT CLUSTER .I 1 A
-9 1 369D298000-23 .AUTO RE-IGNITION CONTROL PANEL ASSY 1 A
-10 369D24136-3 .INDICATOR, AMMETER .1 1 B
-11 MS24523-21 SWITCH (52) ...........I 1 A
-12 7270-1-3 .CIRCUIT BREAKER (CB122) 1 A/B
Alternate
MS24509-A-3
-13 369D298000-29 1 .BRACKET ASSY (Iwr. sw. pnl.) ...............I 1 A
-14 1369D24511 PANEL ASSY (edgelight) 1 A
-15 3691128560-13 .DECAL (anti ice) .......I 1 B
-16 369D26538-501 .VNE CARD (Set) ...........................I
1 B
1-8
ii
o I
~3 \o
a
I; OFF
L~Oil
Lu!I
1 n hn
3
CHAEB~rN
"I
o
7 7 oN
O
LJi:
a a
I
O
57-149-4
Figure 1-4. 250-C20R/2 Engine Installation Kit (Sheet 1 of 2)
1-9
p_ ~F7.
a,
aI
II-I, :I
Y~
I
2\ 9
i3 1~
10
Fi!
i ,e
4
20~gPi
17
II~ o
15
r 1
r-\
I
,r
a
14
a i/
0 O 57-149-5
Figure 1-4. 260-C20R12 Engine Installation Kit (Sheet 2 of 2)

1-10
FIG. UNITS USABLE

NO. NO. ASSY CODE

(Customer Supplied Engine and Battery) 1 A
369B298000-523 KIT, 250-C20R/2 ENGINE INSTALLATION
(Cuetomer Supplied Engine and Battery) 1 B
-11369D298000-11 DOUBLER ........I 1 A/B

-2 1 MS20615-4M RIVET ...1 4 A/B
-3 1369116615-147 DECAL (C. heat/E. anti ice) 1 A/B
-4 369A4003-791 1 .DECAL (K309) ...........................I
1 A
-5 1 AN3370-1 RELAY (K309) ...........................I

1 A
-6 1 NAS1303-1 +BOLT ..................................I
2 A
-7 1 MS14151-2 WASHER ............1 2 A
-8 1 369D290011 1 BATTERY. ...........,(NOT INCLUDED I 1 A/B

-9 1 CA3106ER24- CONNECTOR (battery) 1 A/B
12PB
-10 369D290011-3 .SUPPORT ASSY (battery) 2 A/B
-11 NAS1738B4-2 RIVET ...................................I
AR A
-12 3691)290011-9 1 .I BRACKET ASSEMBLY (TB1) ...............I 1 A
-13 NAS1738B5-2 RIVET, BLIND ........I AR A
-14 MS241171-D1 RELAY (K310) ...........................I

1 A
-15 369A4003-773 DECAL (K310) ...........................I

1 A
-16 MS21043-3 1 .L NUT ......,............................I

2 A
-17 AN960C10L I WASHER ...............................I

4 A
-18 36911298000-33 1 DOUBLER ..............................1

1 A
-19 MS51958-63 SCREW .................................I

2 B
-20 MS24665-151 .COTTER PIN ..........1 2 A/B

MS21042-3 NUT .....(NOT SHOWN 12 A/B
AN96010-L WASHER NOT SHOWN .1 12 A/B
NAS1096-3-6 SCREW. NOT SHOWN .1 12 A/B
MS21919WCH7 CLAMP. NOT SHOWN .1 12 A/B
MS21919WCH19 CLAMP. NOT SHOWN 12 AIB
MS2~919WCH10 CLAMP. ..(NOT SHOWN .1 5 AIB
6851488 ACCUMULATOR ..........(NOT SHOWN .I 1 AIB
E369D298000 WIRE KJT-C20R/2 ...........(NOT SHOWN .I 1 A/B
NOTES:
1
Not required on current configuration 369D helicopters.
See CSP-093 for NHA.
Refer to Allison Operation and Maintenance Manual (GTP-5232-2)
and Allison Bulletin No. 4001.
SECTION 2
2-1. GENERAL INFORMATION. icing system. Operation of engine anti-icing sys-
The engine conversion kit provides for improved tem is accomplished by use of compressor dis-
engine performance and enables increased charge air from a fitting on the engine
altitude operation of the MDHC 500 CModel compressor scroll. The anti-icing air flow is con-
369D and 3693) helicopter. The general mainte- trolled by an electrically operated air shut-off
nance information in this section applies to 250- valve mounted on the scroll. The anti-icing sole-
C20R/2 engine and subsystems installation. Ap- noid which operates the anti-icing valve is lo-
plicable specific maintenance instructions for each cated on the f~rewall shield. Refer to the applica-
subsystem beyond the scope of this manual, refer ble Allison engine manual for additional engine
to the manufacturers publications (Table 2-1). anti-ice information (Table 2-1).
b. Auto re-ipnition svs~em (369D model heli-
2-2. REFERENCE DATA. coDters).

For information concerning optional or standard
NOTE
helicopter components which interface with the
250-C20R/2 engine system, refer to NMI and For 369D helicopters equipped with auto re-
369D or 3693/3691" IPC (CSP-D-4, CSP-EIF- ignition systems, removal of all components
4). and associated wiring must be removed to
facilitate incorporation of new auto re-
2-3. DESCRIPTION. ignition system.
a. Engine anti-ice~svstem. The cable The new re-ignition system consists of a

auto
controlled system (if installed) is replaced with new switchassembly (XDS9) placarded RE-ION
an electrically controlled anti-ice system. Com- P RST, auto re-ignition relay K104, switch (S11)
presser bleed air supplied to inlet guide vanes placarded TEST, and terminal (diode) board as-
and the number one bearing housing is sembly (TB1000) and associated wiring. The au-
controlled by the ANTI ICE circuit tomatic re-ignition system provides a means to
breaker/switch CB122 mounted on the instru- automatically re-ignite the engine when either
ment console switch panel. Moving the switch to N1 or NR speed drops below their specified lim-
ANTI ICE energizes a solenoid mounted on the its. (Refer to appropriate helicopter model PFM
compressor scroll that controls the engine anti- for system operation).
Table 2-1. Reference Documents
US Army
Technical Manual
or Manufacturers
System/Installation Manual Maintenance Level
Allison 250-C20R Operation and GTP-5232-2 Organizational

Maintenance Manual
Kit, Conversion, 250-C20R/2 369D293000 Organizational

Engine for 369D and 3693
Installation and Service Manual Facet Kit No. Facet Enterprises, Inc.
Scavenge Lube Oil Filter 1741050-01
Heavy Duty (17 Amp Dr, 20 Cell) CSP-093 Organizational

Battery
2-1
PACKING
(NOTE 2)
REDUCER
SNUBBER
PA C K I NG UNION (NOTE 2)
(NOTE 2)
ITF~i
EL~OW
NUT
FITTING
ANGLE
(NOTE 1)
CLAMP
SCREW INSERT
WASHER
BOLT
PACKING JUMPER
JUMPER
(NOTE 2) ASSEMBLY
NUT ASSEMBLY
(NOTE 21 WASHER
(NOTE 2)
ELBOW
BOLT
d
NOTES:
GENERATOR
i. APPLIES ONLY TO LOWER MOUNT.
m~
2. PARTS SUPPLIED FROM CONVERSION KIT.
3. REMOVE CLUTCH ASSEMBLY WITH SEAL, COUPLING
AND ASSOCIATED HARDWARE IN TACT.
4. INJECT SEALANT 15, TABLE 2-2) INTO CAVITY OF 1\PACKING
SPRING ASSEMBLY ATTACH POINTS. (NOTE 2)
,17
ONUT 47-1303-1
Figure 2-1. Interchangeable Engine Buildup Components 250-C20B and 250-C20R/2 (Sheet I of 3)
2-2
PACKING
(NOTE 2) COUPLING
REDUCER
SEAL
HOSE
NUT~ CLUTCH
(NOTE 2) WASHER ASSEMBLY
(NOTE 3)
AS EMBLYPACKINGFIT ING
ANGLE ASSEMBLY
[NOTE 2)
CLAMP
NG SWITCH
BUSHING
PA(NOTEIKC)2 BOLT
O GENERATOR TACH WASHER
FITTING
O
NUT
GASKET
WASHER
TEE
//e\
NUT
GASKET (NOTE 2)
REDUCER
PACKI
(NOTE 2) SNUBBER .I
(NOTE 2)
PACKING
INOTE 2)
DRAIN VALVE
o .oraoMI
~O
klTUBE 47-1303-2
Figure 2-1. ~nterchangeable Engine Buildup Components 250-C20B and 250-C20R12 (Sheet 2 of 3)
2-3
NUT
P WASHER
COTTER PIN
j~C
--I
r (NOTE 2)
i;
WASHER
;_
~I 1-
CLAMP
SPRING
ASSEMBLY
(NOTE 4)
EXHAUST PIPE
O) (ROTATED)
O SPR ING ASSEMBLY (TYPICAL FOR

UPPER AND LOWER) L
C
cC
~I
LCC~
STA.
_
~7)
50
U7./V C
C
C
li~-
WASHER .J WASHER
BOLT SUPPORT
c
f~
NUT
CLAMPj(
Cf"
TERMINAL
BLOCK
300
WASHER
J
A WASHER WASHER
CLAMP SCREW
O WASHER SCREW
ACCESS SCREW
DRIVE
TUBE O
CLAMP
BOLT
WASHER/ ,SCREW
CLAM
PUMP SEAL
DRAIN TUBE
O 47-1303-3
Figure 2-1. Interchangeable Engine Buildup Components 250-C20B and 250-C20R/2 (Sheet 3 of 3)
2-4
Engine oil system. The Allison 250-C20R/2 NOTE

C
engine requires a scavenge oil filter (provided by
The clutch assembly may be removed
manufacturer), which will clean the oil to a
with seal, coupling and associated hard-
much finer degree and extend flight hours be- reinstalled in 250-
ware in tact and
tween oil changes. The filter has a visual poppet
C20R/2 engine.
indicator providing impending bypass warning
when the differential pressure the element is 250-C20R/2 17
on Th, engine requires a
above 7-e 1 PSID. hr, 20 cell battery (369D290011).
amp
A new engine oil tank is provided to eliminate d. Remove 13 amp hr battery (refer to Bat-
air in the oil system and reduce scavenge back
tery Removal, HMI).
pressure.
NOTE
d. Electrical system. The electrical system bat- For 369D helicopters serial numbers 003-
tery is changed from a 13 amp hr to a 17 amp 1149 and 1151-1184, terminal board TB1
hr battery to meet the increased starting ampere must be relocated to allow for clearance of
requirements of the 250-C20R/2 engine. Helicop- the battery. Refer to CSP-093 for instslla-
ter (battery system) wiring size (AWG) is also tion instructions of battery and relocation
increased to compensate for the larger flow of instructions of TB1.
current. Modification of the lower switch panel
(3691) model helicopters with slim-line instru- 2-7. ELECTRICAL BONDING CONNECTIONS.
ment panel) eliminates the large BAT-FXT Refer to the maintenance instructions provided
PWR-OFF circuit breaker switch (52) with a in HMI.
smaller 52 switch. Wiring size is also changed to
facilitate the installation. For 369D model heli- 2-8. MODIFICATIONS.
copters serial numbers 003-723, incorporation of
two relays K309 and K310 are installed. 2-9. INSTRUMENT PANEL.
(Refer to applicable maintenance instructions pro-
2-4. TROUBL~SHOOTLNG. vided in HMI)
(Refer to HMI)
a. Identify and mark wires for removal.
2-5. PREPARA~ION.
Preparation for installation of the 250-C20R/2 b. Remove TOT and torque indicators.
engine includes the following:
_c. Remove ammeter as follows:
Identify all removed components including

_a.
attaching hardware and components removed to 1. On 369D helicopters, remove instrument
gain access to work: areas. Protect components cluster.

from damage and foreign matter until reinstalled.
2. On 3693 helicopters, remove ammeter
b. Check all electrical switches for OFF posi- gage.
tion.
d. Remove V,, placard.
Open left and right engine access doors.
_c. TOT and torque indicators pro-
8 Install new
vided.
2-6. REMOVAL OF HELICOPTER EQUIPMENT
f. Install new ammeter as follows:

a. Remove crew and passenger compartment
seats. 1. On 369D helicopters install instrument
cluster (369D296305-23).
b. Remove engine (250-C20B).
(Refer to Engine Removal, HMI) 2. On 3693 helicopters install ammeter.
Stripping the engine (250-C20B).

_c. g. Install new V,, placard according to heli-
(Refer to Engine Stripping, HMI) copter model and actual helicopter gross weight.
Similar engine subsystem components of 2-10. ANTI ICE CABLE SYSTEM
250-C20B and 250-C20R/2 engines are identified REMOVAL (250-C20B).

in Figure 2-1. Remove parts and retain for 250- (Refer to Anti icing Valve Control Cable Re-
C20R12 engine installation. moval, HMI)

2-5
NOTE 2-14. WIRING MODIFICATIONS.
Disregard references to cable reinstallation,

adjustment and operational, check. I WARNING
WI\RNI.O
I
half of decal, apply
Before removing or installing compo-
Using sharp knife, remove
nents of electrical system, ensure that
side identified with OFF-CABIN HEAT-ON to
all electrical power is OFF. If units are
heat duct panel (Ref. Fig. 2-2).
not immediately replaced, ensure that
all electrical connectors are suitably
capped andstowed, and that all loose
cables are properly insulated and
Table 2-2. Special Tools and Equipment
stowed, to prevent possibility of short-
Item
No. Nomenclature Manufacturer
ing. Serious iqjury or death could re-
suit from voltages present in electrical
1 Drill, portable Commercial
system.
2 Bit, drill No. 1/8 Commercial
(0.1250) 2-15. ELECTRICAL WIRING REPLACEMENT.
Refer to Table 2-4 and Figure 2-5 for wiring
3 Bit, drill No. 1/2 Commercial
(0.500) changes and descriptive information. For infor-
mation on wire routing, refer to Figure 2-4.
NOTE
2-11. INLET ASSEMBLY DOUBLER
INSTALLATION. 369D model helicopters serial nos. 003-723
(Ref. Fig. 2-3) do not have an external power relay or bat-
tery relay. BATTERY-EXT PWR-OFF

switch (S2) connects the de main power bus
_a. Determine correct position of doubler over
to either an external power source or the
inlet assembly and mark.
nicad battery.
b. Using drill motor and number 1/8-inch a. Refer to HMI for accessing start relay, re-
drill bit (2, Table 2-2), drill four equally spaced verse current relay, battery relay, start genera-
0.128-inch holes at marks. tor, external power relay and external power re-
ceptacle. Perform steps 1. and 2. only for 3691)

series helicopters without external power or bat-
_c. Coat bare metals and doubler (Ref. Fig. 1-
tery relays.
4, item 1) with primer
(1, Table 2-3), allow to dry. 1. K309 Relay installation.
(369D helicopters serial nos. 003-723 only).
9. Apply primer (2) to same surface areas, al- (Ref. Fig. 2-6)
low to dry.
NOTE
For detailed wiring instructions, refer to Ta-

8 Align doubler over inlet assembly and in-
ble 2-4 and f~gure 2-5.
stall four rivets (3) with wet primer (7).
Using kimwipes (8, Table 2-3) and
(a). al-
f. Apply sealant (4) to edge of cohol (9) cleanarea for application of decal
doubler, allow to dry. K309; apply decal as shown.
2-12. ENGINE OIL TANK REMOVAL~(250-C20B) (b). Using hardware provided, install relay
K309.
(Refer Engine Oil
to System, HMI)
Retain all hoses and fittings for reinstallation.
(c). Attach diode assembly to terminals
K309-X1 and K309-X2.
2-13. ENGINE OIL TANK INSTALLATION
2. K310 Relay Installation.

(Refer to Engine Oil System, HMI)
(3691) helicopters serial nos. 003-723 only).
Install using all existing hoses, fittin~s and new
(Ref. Fig. 2-6)
packings.
(a). Using kimwipe (8, Table 2-3) and alco-
hol (9) clean area for application of decal K310;
apply decal as shown.
2-6
ANTI-COLL PITOT RE-ION

BAT o LT HTR T~ST O
EXTPWR OFF OFF OFF

ON- START SCAV POS UTIL LTR
OPUMP AIR ANTI-ICE PWR
O o
OFF OFF OFF OFF I OFF
OEDGE LIGHTEO PANEL

OVS
i4i
OFF LTEST
DECA
(NOTES i, 2)
CABLE SUPPORT
BLOCK (3 PLACES)
OFF
CABINlnlCE
ANTI-OF
ENG
HEAT
DECAL
d (NOTE 1)
OUTER BOX/ NOTES:
i. REMOVE CROSS SECTION AREA OF DECAL.

CONTROL HANDLE 2. EFFECTIVE 369E HELICOPTERS ONLY.
Is CABIN HEAT DUCT
HEAT DUCT
(6 PLACES)
MOUNTING SCREW
47-1307A
Figure 2-2. Panel Decal Applications 250-C20R/2
2-7
t! i
DOUBLER
(NOTE I)
(NOTE 2)
FORWARD VIEW LOOKING UP FROM

~I ENGINE COMPARTMENT AT INLET ASSY
P:
NOTES:
L DRILL HOLE 0.128-INCH, 4 PLACES.
INSTALL R IVETS (MS 20615-4M) WITH
B
WET ZINC CHROMATE (7, TABLE 2-3)
2. APPLY SEALANT (4, TABLE 2-2)
j ON ENGINE SIDE OF INLET ASSY
CONTROL CABLE TO
~il VALVE ATTACHMENT
47-1308A
Figure 2-3. Inlet Assembly Doubler Installation

2-8

Commercial Producta
Item Specification
No. Material No." Name/ No. Menu factu rer
1 Primer, Epoxy HMS 15-1100 Advance Coating and
Type I Chemicals
2213 N. Tyler
So. El Monte, CA 91733
2 Enamel, White Epoxy HMS 15-1100 Advance Coating and

(Color No. 17875, Type II Chemicals
Fed Std 595)
3 Rivet MS20615-4M (4)

MS20470AD3
NAS1738
MS20426AD3
NAS1738B5-2
4 Compound, Sealant MIL-S-38249 Pro Seal 700 (3,4) Products Research Corp.
Glendale, CA.
5 Sealant, High Temp. GE RTV-1OB (3,4) General Electric
6 Lockwire (diameter MS20995C (3,4)

as required)
7 Primer, Zinc Chromate MIL-P-8585 or
TT-P-1757
8 Kimwipe (3)
9 Isopropyl alcohol TT-I-735 (3)
10 Lacquer, black acrylic HMS15-1083 (5) Advance Coating and

Chemicals
NOTES: (1) Numbers are U.S.A. Specifications symbols are defined as

and Standards. Prefix
follows: AMS American Standard; MS
Material Military Standard; MIL Military
Specification; Single, double or triple alpha prefix of same letter Federal Specifica-
tion; AN Air Force-Navy Aeronautical Standard; NAS National Aerospace Standard.
(3) Use best comparable grade material when conformity of available materials of same
type with listed Specification No. cannot be determined.
(4) Materials supplied in kit.
(b). Determine correct position of doubler (f). Align doubler, and install rivets (3)
and align doubler with existing fastener holes. with wet primer (7).
(g). Using hardware provided, install relay

(c). Remove existing fastener holes as re-
K310.
quired and drill holes in doubler to match.
(h). Attach diode assemblies to terminals

(d). Coat bare metals and doubler with K310-X1 and K310-X2, and K310-X1 and K310-
primer (1), allow to dry. Al.
(e). Apply primer (2) to same surface ar- b. Identify and mark wires for (Ref. Fig. 2-5).
eas, allow to dry. replacement.
2-9
;o~
TURBINE OUTLET
TEMPERATURE
(TOT) INDICATOR
(NOTE 1)
TORQUE GAGE
INSTRUMENT O~
APU RELAY CLUSTER
K309 3-PACK
Jloo APU E ot~ 0 0

00
RECEPTACLE
)I I*nOlLIWIIIONr I
AUTO RE-IGNITION o
CONTROL ASSY
s~lrln
0-
~210000
gooo oil o
o/m~o o o
o INSTRUMENT PANEL-SLIMLINE
VNE
CARDS
TORQUE
GAGE
o
AMP
loil GAGE
o
TOT
6~" o DECAL
GAGE
0 IINSTRUMENT
NSTRUMENT T-PANEL
CB122
47-1302-1B
Figure 2-4. Component Locations and Wire Routing Installation (Sheet 1 of 5)
2-10
CSP-1OO Opt Eqpt Manual Section 2
EXISTING FUSELAGE
WIRE HARNESS, ROUTE EXISTING WIRE HARNESS
PILOTS NEW WIRES WITH FROM PILOTS CYCLIC STICK
FLOOR EXISTING BUNDLES
K310
SEAT STRUCTURE
GROUND WIRE
FROM (-)SIDE
OF BATlERY
CONNECTOR
FEEDER FROM K309-A2 IS TO BE ROUTED

THROUGH THE TOP HOLE AS SHOWN.
CARE IS TO BE TAKEN WHEN SECURING
WIRE HARNES S SO AS NOT TO CREATE
O II CONTROL RODS OR LINKAGE
3 U1D AWG FEEDER EXISTING WIRE

WIRES FROM VOLTAGE
HARNESS TO
REGULATOR
K310 TO TB1D1 DISTRI BUTION STA
INCONSOLE MODULES 70. 40
LOOKING INBOARD FROM BL 20.00 LH

VIEW A -A
J100
EXI. POWER BC1 AI
RECEPTA CLE FEEDER 1Y10 AWG
BL20.75 SEAT WIRES, FROM K310-A1 FEEDER FROM EXT.
FEEDER FROM J 100 BL6.00
RH TO K3D9-A 1 STRUCTURE TO TBIDI i, 4 7 PWR RELAY K309-A2
RH
IN CONSOLE TO K310-A1
GROUND FEEDER
FROM 5100(-) TO E4
K309 EXTERNAL
POWER RELAY
1 1
I I
g
gJ K310
E4 BATTERY
>z RELAY
(NOTE 5)
;o K310RELAY (NOTE 41BAT~RY

ENGINE COMPARTMENT
K300-BATT TO K310-A1
FEEDER FROM ENG INE
COMPARTMENT K310-A 1 BLD.00 A~1
TO K3D9-A2 WL 0.00
GROUND W4 AWG, FEEDER H4 AWG
FROM TERMINAL OF FROM TERMINAL OF
BATTERY CONNECTOR BAT~RY CONNECTOR
TO El TO K310-A2
LOOKING AFT-FROM STATION 64.365 47-1302-2A
2-11
STA
71.00 FEEDER 2#ERI~V AWG
FEEDER
(I 1( EXISTINGENGINE
WIRE HARNESS
DIOI~E
FROM EXT.
PWR. RELAY
lI ASSY
K309 TO
BAT.RELY K310 WL. 16.00
SHIP STRUCTURE
GROUND SIDE
OF EXT. POWER MS21919WCH-13
RECEPTACLE MS21919WCH-10~11 CLAMP
J100TOE4 CLAMP
GROUND STUD MAIN FEEDER FROM POS ITIVE SIDE FROM
ENGINE COMPARTMENT EXT. PWR. RECEPTACLE
VIEW LOOKING OUTBOARD FROM BL 10. ORH

VIEW B-B
O
WIRE CLAMPING METHOD (NOTE 2)
WI 34. 500
EXISTING #2 AWG FEEDER FROM 12 AWG FEEDER FROM

ENGINE WIRE K300-GEN. TO G3D0-B K301-A2TO G3DO-C
HARNESS
TO 5303
K300 REVERSE
CURRENT
%2 AWG GROUND R~URN
RELAY I I I
FROME12TOG300f
K301
START RELAY
I Ij
i I I
tL:
I I
ENGINE WIRE i
HARNES S FROM
r-
MID FUSEIAGE AREA
O
ENGINE BAY,
,___,
LH SIDE-LOOKING FWD
BL O. Mi
#2 AWG FEEDER FROM K309 A2
WL 0.00 47-1302-3
TO K300 BATT (NOTE 1)
2-12
369DIEIFF HELICOPTERS
TB1
13690 SN 724 SUBS: 369E/369FF-ALL)
El
P9
BAT~RY RELAY
~K310(NOTE 5)
P110
~9"
b~j
J/P9
JIP110 Og; 369D HELICOPTERS ISN 003-765)
00
BATTERYRELAY
K310 (NOTE 5)
On
n
3J
W ;x
o,
t
Q
BATTERY RELAY
TB1
K310 (NOTE 4)
(NOTE 6)
O BATTERY COMPARTMENT AREA

47-1302-4
2-13
Section 2 Opt Eqpt Manual CSP-1OO
#2AWG AEDER t2AWG REDER

FROM K301-A2 FROM K300-GEN.
TO G300-C TO 0300-0
EXISTING ENGINE
E12
WIREHARNESS
TO 5303
I ~K300 REVERSE
CURRENT RELAY
#2AWG GROUND I i
RETURN FROM/ I I ~K301 START
i
E 12 TO G300-E I RELAY
rl
OML
ENGINEWIRE
J NESS FROM
FWD FUSELAGE AREA
1;
X2AWG REDER FROM
BL 0.00 K309-A 2 TO K300 -BATT
WL D.00 (NOTE 1)
O ENGINE BAY RH SIDE-LOOKING RND (NOTE 4)

NOTES:
1. SEPARATE FEEDER FROM ENG INE WIRE HARNES S UPON EX ITING CONDU IT AND
MA INTA IN SEPARATION.
2. MAX SPACING DISTANCE BETWEEN CLAMPS NOT TO EXCEED 8.0 IN. THIS IS
REQUIRED TO REDUCE TEMPERATURE RISE UNDER HEAVY CURRENT LOAD.
3. EFFECTIVE 369[) (SIN 003-724) HELICOPTERS ONLY.
4. LOCATION EFFECTIVE ON 369[3 (SIN 725 THROUGH 765) HELICOPTERS ONLY.
RELOCATION TO PILOTS FLOOR (UNDERS IDE) IS REQUIRED. REAR TO FIGURE
2-6 FOR RELOCATION INSTRUCTIONS.
5. EFRCTIVE CURRENT CONFIGURATION 369[3 AND 369E HELICOPTERS.
6. RELOCATION OF TB 1 1S REQUlffED TO ALLOW INSTALLATION OF 17 AMP HR
BATTERY, REAR TO CS Pd93 FOR INSTRUCTIONS. 47-1302-5
2-14
9 NSTRUMENTCLUSTER
G300 i
START P534A2 STARTER P533A2 II-
r c B
SWITCH (40.0 IN.) GENERA (39.0 IN.)
~e I- +I
+28
,,3 P535A2N
E
Ic
II
1
o
31 IC,
-~i-----l
I (26.01N.)
K300
K301 REVERSE
812 P-4-J
START CURRENT
RELAY RELAY E
L -O A2 853282 TT
I Al D
(16.5 IN.), I-- AMP GAGE
J-9-P I
1
P528 D505CZO
M33
E 0505820 LOAD
E13 (230.0 IN.) (60.0 IN.)
X2
oso~clo
I
I---, -I-- Fl ,,___~, _,D501820 8ATT
~I (96.0 IN.)- (60.0 IN.)
+L.P502A4___ K310\ I --Fil D501 C20
BATTERY
(48.0 IN.)
_ _
17AH BATT I LU~96.0 IN.)

RELAY\ RELA
P1OB
P501A4
(96.01N.)
I JUMPERC,
L--~OA21A1 Y-EcI3s(1 853242
ie.o IN.,
\I
K309
EXTPWR
RELAY
J100
I __~P125582:
P502A22Q4i
1_
-~A29--------
IAl
0.2(A51P)NI
El EXTERNAL
MASTER (51.0 IN.) (20.0
52 POWER
SELECT 1 r---------
1BATTERY P!?54A2N_ RECEPTACLE
~x1X2I
SWITCH
30i- - -(60.0PWR
_
IN.) IN.)
P521A20NJO_ (OFF III 84
TaBOIN] Ip
OLE~PWR_ P503A22 III
I L,1,J 7i20.0 IN.) fTT-~ L---~
(II
83
II
TB101 ;II TERMINAL LUG
II TERMINAL LUG (M7928/1-27)
I
TEFLON TEFLON
--~I-Z__B, P505C (3-10)I (M525036-102) TUBING TUBING
(96.0 IN.)
I
W1 (I DIODE DIODE
CIRCUIT 11 TERMINAL LUG
BREAKER
PANELI W3
I
JI O (MS25036102)
BUS
~t -I~:J J [lN5402) DIODE ASSEMBLIES
r
W2 I
SWITCH PANELr
BuS BARL
CB122 P-9-J
8307
Id ja6?--P516020_ M(BEZO
i
(63.LllN)--~r (140.01N.) (48.0 IN.) ANTI-ICE
SPBBB ~i 3 SDLENOIO
P535F20N VALVE
r0~ (48.0 IN.)
2
j
LEGEND: 812
DASHED LINES INDICATE NEW OR REPLACED WIRES OR
COMPONENTS
NOTES:
O USE SLEEVING (HS5330-2628) TO INSULATE WIRES

O EFFECTIVE ON 3691) MODEL HELICOPTERS ONLY
O CRIMP DIODE (lN5551) LEADS AND WIRES INTO TERMINALS OF EFFECTIVE ON 3698 MODEL HELICOPTERS ONLY
CONNECTOR
O EFFECTIVE ON 3690 SERIAL NOS. 003-723 MODEL HELICOPTERS

O INDENTIFY SLEEVING ON THREE #10 AWG WIRES WITH 8505 C ONLY
(3-10)
O NUMBER IN PARENTHESES INDICATES WIRE SEGMENT LENGTH

THAT MUST BE MAINTAINED FOR PROPER INSTALLATION AND
OPERATION
47-1304A
Figure 2-5. 250-C20R12 Wiring Diagram
2-15
Section 2 Opt EQpt Manual CSP-100
Table 2-4. 250-C20R/2 Wiring Data List
Wire From Termination To Termination Material
P534A2 G300-C M25036-127 K301-A2 M25036-127 2 AWG
P533A2 G300-B M25036-127 K300-GEN M25036-127 2 AWG
P535A2N G300-E M25036-127 E12 M25036-127 2 AWG
P532B2 K301-A1 M25036-127 K300-BATT M25036-127 2 AWG
D505B20 M33-(load) M39029/ 22-191 P9-E M39029132-259 20 AWG
D501B20 M33-(batt) M39029/ 22-191 P9-r M39029/ 32-247 20 AWG
P532A2 K300-BATT M25036-127 K310-A1 M25036-127 BAWG
P1265A2 K309-A1 M25036-127 5100 (t) M25036-127 2 AWG
P1254A2N E4 M25036-127 Jloo M25036-127 2 AWG
t P505e I(310-A1 M25036-127 TB101-1,-4,-7 MS25036-lll 10 AWG
P502A22 S2-3 MS25036-149 K310-X2 a MS25036-102 22 AWG
P503A22 82-1 MS25036-149 K309-X2 a MS25036-102 22 AWG
P521A20N S2-2 MS25036-149 E3 M525036-102 22 AWG
PS01A4N El. M25036-127 P108 4 AWG
PS02A4 K310-A2 M25036-127 P108 4 AWG
P535F20N P307-2 M39029/ 5-115 E12 M39029/ 22-191 20 AWG
Q516G20 CB122-2 M825036-149 P9-f M39029/ 32-259 20 AWG
6516E20 P307-1 M39029/ 5-115 SP888-1 M39029/ 22-192 20 AWG
Q516F20 J9-f M39029131-240 SPS88-2 M39029/ 22-192 20 AWG
D501C20 J9-r M39029/ 31-228 K310-A1 M525036-105 20 AWG
P1255B2 K310-A1 M25036-127 K309-A2 M25036-127 R 2 AWG
Jumper K310-A2 MS25036-105 K310-X1 MS25036-102 22 AWG
Diode- K309-X1 M525036-102 K309-A1 M7928/ 1-27 ZN5402

jumper (cathode) (anode)
Diode- K309-X2 MS25036-102 K309-X1 M525036-102 IN5402

jumper (anode) (cathode)
Diode- K310-X2 MS25036-102 K310-X1 MS25036-102 INS402

jumper (anode) (cathode)
Following Wire Terminations Effective 369D Helicopters Only

(Substitute with matching wire above)
P532A2 K300-BATT M25036-127 K309-A2 M25036-127 2 AWG
DS01C20 J9-r M39029/ 31-228 K309-A2 M25036-127 20 AWG
DS05B20 P9-E M39029/32-259 P4-E 20 AWG
DS01B20 P9-r M39029/ 32-259 P4-D 20 AWG
P505C K310-A1 M25036-127 W1, W2, W3 10 AWG
NOTES:
Preferred wires are M5086/2-20-9, M22759/34-20-9 and M81381/12-2-9.
t Requires I.D. sleeving with wire no. P505C (3-10) on it.
Install boot MS25171-1S on crimping lug.
wire end before
Install boot MS25171-2S on wire end before crimping lug.
Terminations vary with battery configuration.
2-16
STA STA
71.00 74.00
/j
100
16. 00
D(TERNAL POWER RELAY (K309)

O (VIEW LOOKING OUTBOARD FROM BL 10.0 RH)
5~ n/Y
J
WASHER
RELAY
BOLT
81
JIP9
JIP110
TB1
BAT[ERY RELAY
K310 (NOTE 1)
BAT~RY COMPARTMENT AREA bl-ULP-l
Figure 2-6. Battery (K310) and External Power (K309) Relay Initial Installation (Sheet 1 of 2)
(369D Helicopters Serial Nos. 003-723)
2-17
TRACE
(NOTE 3) t
CANT STA.SCREW
WASHER
64.36
i lr (NOTE 2)
---I
+re (NOTE 4)
i. 87 3.00
1.28
2.09
PILOTS
BL 20.75 IH FLOOR
la DOUBLER
WASHER
RELAY NUT
O
NOTES:
O
i. LOCATION EFFECTIVE FOR 3690 ISIN 725 THROUGH 765) 3. DRILL HOLE 0. 220-0. 226INCH, 2 PLACES. INSTALL
HELICOPTERS ONLY, RELOCATE TO PILOTS FLOOR RIVETS (MSX)dlOAD31AS REQUIRED WITH WET
(UNDERS IDE), REAR TO VIEW C. CAP AND STOW ZINC CHROMATE (7, TABLE 2-3).
WIRE ENDS, 4. DRILL HOLE 3132 INCH, 10 PLACES. INSTALL RIVETS
2. REMOVE EXISTING FASTENERS AS REQUIRED TO (MS X)470AD3) AS REQU IRED WITH WET Z INC CHROMATE
INSTALL -33 DOUBLER. LOCATE AND DRILL HOLES (7, TABLE 2-3).
47-1319-2
TO MATCH EXISTING FASTENER HOLE LOCATIONS.
Figure 2-6. Battery (K310) and External Power (K309) Relay Initial Installation (Sheet 2 of 2)
(36911 Helicopters Serial Nos. 003-723)
IT~
CAUTION
HMI.)(Refer to appropriate maintenance instructions in
Wire No, PS32A2 length (118.0 inches)

must be maintained for proper opera-
tion of amp meter gage.
I ~II
WARNING
NOTE Ensure electrical connections are se-
cured and properly spaced and insu-

Do not crimp terminals on wire P632A2 lated to prevent possibility of shorting.
until wire has been installed in the con-
e. Trim, connect and secure wiring to fit in-
duit of the aircraft belly.
stallation (Ref. Table 2-4).
Wires provided in this kit are excessive
in length to allow installation in ail ver- 2-16. ANTI ICE SYSTEM MODIFICATION
sions of aircr~t. Cut wires to proper (Ref. Pig. 2-7)
length routing
after (using existing
clamps and routing locations) and termi-
nate with hardware provided. I -II
WARNING
Use clamping method (Ref. Pig. 2-4) in Before removing or installing compo-
areas where no structural clamp support nents of electrical system, ensure that
is provided and to maintain separation all electrical power is OFF, If units are
between all #2 AWG wires and other not immediately replaced, ensure that
ship harnesses located in the engine com-
partment. capped and stowed, and that all loose
cables are properly insulated and
_c. (Ref. Figures 2-4 and 2-5) Remove wires
stowed, to prevent possibility of short-
and install replacement wiring using provided
hardware.
ing. Serious injury or death could re-
sult from voltages present in electrical
d. Install components removed in step a. system,
2-18
NOTE 6. Trim, connect and secure wiring to appro-

The 250-C20R/2 engine system requires priate switches and associated components to fit
installation (Ref. Table 2-4).
modification of the following:
For 369D model b. Electrical anti-ice system wiring installation
helicopters, the lower
switch 3693 helicopters.
panel (369216410-15) is modified
by enlarging existing hole from
BATTERY-EXT PWR-OFF switch S2,
1. Remove screws and edgelighted panel from
switch panel.
allowing installation of two new switches
(ANTI ICE 52 and BATTERY-EXT 2. Mark and drill holes for circuit breaker
PWR-OFF CB122). A newedgelighted (Ref. Fig. 2-7), using numbers 1/8 and 1/ 8-inch
panel is provided for replacement of old. drill bits (2, 3, Table 2-2).
For 3693 model helicopters, the

(a). Measure from center of POS LT
edgelighted panel (369026460) is modi-
switch, 0.90-inch center right and mark.
fled to allow installation of the ANTI
ICE circuit breaker switch CB122. If no (b). Measure from mark, above and center
space is available, locate switch to opera 0.375-inch and mark for switch alignment hole.
tors preference.
(c). Drill a 0.500 0.505-inch diameter hole
_a. Electrical anti-ice system wiring installation at first mark.
-3691) helicopters.
(d). Drill a 0.121 0.126-inch diameter
NOTE hole at alignment mark.
Lower switch and circuit breaker (e). Install circuit breaker CB122 to switch
edgelighted panel may be attached by 4 or panel (Ref. Fig. 2-7).
5 screws depending on effectivity.
(f). Remove plug button from edgelighted
1. Remove screws and
edgelighted panel from panel to accommodate circuit breaker CB122.
lower switch and circuit breaker panel. Discard
3. Using sharp knife, remove half of decal,
panel; replacement is provided. Retain screws for
reinstallation. apply side identified ANTI ICE/OFF to
edgelighted panel as shown (Ref. Fig. 2-2).
2. Remove 369116422-49 angle bracket and 4. Trim, connect and secure wiring to circuit
switch 52. Discard bracket and switch; replace- breaker CB122 and associated components to fit
ment provided. Retain hardware for reinstalla-
installation (Ref. Table 2-4).
tion.
NOTE
3. Enlarge vacated hole left by switch 52 on
Installation of circuit breaker CB122 may
panel (369H6410-15) per dimensions shown.
require modification of console on 3693
model helicopters, serial nos. 318 383 only
4. Install new angle bracket (369116422-29)
(Ref. Fig. 2-7).
with switch (52) and circuit breaker (CB122) at-
tached; install
onto panel using e~isting hard- 5. Using eldsting hardware install screws and
ware.
edgelighted panel onto switch panel.
5. Install new edgelighted panel provided, us- 6. Perform Operational Check of aircraft elec-
ing e~sting hardware. trical systems (refer to appropriate PFM).
2-19
.121
DRILL DIA
.126 .375
SWITCH PANEL .500

.90 DRILL DIA
(369826460-273 .505
arurl-cou
crt. O 41~7 R~:F"O
O
POI
ANTI-ICI PIYR
oo o ,O
or~
EDGE LIGHTED SWITCH PANEL

-29 BRACKET ASSY
(INSTRUMENTT-PAN~-
(NOTE 2)
MS25036-103
SWITCH TERMINAL LUG
(S2) W2
SWITCHIBREAKER BUS 1.001- -1 CONSOLE
000
(CB122)
JUMPER
BAR
.OB -(t12 (NOTE 1)FACE
TERMINAL LUG I~;;;;]
110812211
MS 25036-149
08122
ANTI-ICE
O LOWER SWITCH
S(LENAP
IDE VIEW)
SWITCH
6G20--
d FRONT VIEW OF SWITCH PANEL
.750 REAR VIEW OF SWITCH PANEL
.888-1 WIWITCH INSTI\LLAIION)

31
i
(369H6410-15
"7 O /I .O I.LOWER PANEL) ~;;I
2. 187
0666 0 OO (NOTE 4) Mma
000
o
ss~
0
O
b ooo
o Llounl
o la. I
o o o~O O 0--
4XR.06
LOWER SWITCH PANEL MOD IFICATION A LOWER SWITCH PANEL
NOTES:
i. TR IM CONSOLE TO ALLOW FOR EXTENS 1ON OF CB122. 3. ENLARGE EXISTING HOLE TO D IMENS IONS SHOWN
369E HELICOPTER SERIAL NOS. 318-383 ONLY. (REMOVE SHADED AREA).
2. REPLACE EXISTING ANGLE BRACKET WITH -29 BRACKET 4. ALL PANEL SWITCHES OMIT~D FOR CLARITY.
ASSEMBLY PROVIDED. ATTACH SW ITCHES 82 (MS 24523-1)
AND CB122(7270-1-3) PROVIDED. 47-1318
Figure 2-7. Anti ice System Modification Instrument Panel
2-20
CSP-100 Opt EQpt Manual Section 2
2-17. AUTO RE-IGNITION MODIFICATION. re-ignition system (refer to appropriate PFM).

(369D helicopters only)
2-18. SCAVENGE OIL FILTER
I -II
WARNING INSTALLATION.
(Ref. Fig. 2-10)
Before removing or installing compo- a. Remove engine oil tank in hose

nents of electrical system, ensure that (369118305) assembly.
all electrical power is OFF. If units are
b. Remove engine oil tank out hose
not immediately replaced, ensure that
(369118306) assembly and union (AN815-8D).
capped and stowed, and that all loose _c. Install oil f~lter assembly per enclosed Facet
cables are properly insulated and scavenge oil filter assembly installation instruo
stowed, to prevent possibility of short- tions.
ing. Serious iqjury or death could re-
sult from voltages present in electrical 2-19. ENGINE INSTALLATION AND
system. ALIGNMENT (250-C20R/ 2).
(Refer to 369D HMI Vol 1, CSP-D-8.)
NOTE
For helicopters with auto re-ignition system 2-20. ENGINE RIGGING AND ADJUSTMENT
installed, all auto re-ignition system compo- (250-C20R/ 2).
nents (Sll, XDSS, K104, K304) and associ- (Refer to 369D HMI Vol 1, CSP-D-8.)
ated wiring must be removed. Refer to ng-
ure 2-8 for component locations. 2-21. ENGINE OPERATIONAL CHECK
(250-C20R/ 2).
_a. Remove screws and edgelighted panel from (Refer to appropriate PFM Section 4, (CSP-D-1,
switch panel. CSP-E-1.)
b. Remove switch Sil, switch assembly XDSS, 2-22. WEIGHT AND BALANCE.
relays K104 and K304 and associated wiring.
2-23. GENERAL.
c. Fabricate cover as required for hole vacated Revise weight and balance pages in helicopter log
by switch XDSS. book to reflect modification of helicopter. Weight
and balance data changes from installation of
d. Install cover on instrument panel. 250-C20R/2 engine conversion kit are listed in
Table 2-5. After installation of 250-C20R/2 en-
8 Paint out lettering at previous auto re-
gine conversion kit, incorporate changes in heli-
ignition switch location with acrylic lacquer (10,
copter weight and balance records (Ref. Sec. 08-
Table 2-3).
10).
f. Install plug button on edgelighted panel. Table 2-5. Weight and Balance Data
Model Weight Arm Moment
g. Install new auto re-ignition control panel (pounds) (inches) (in.-lb/ 100)
provided.
3693 Helicopters 369D298000-519
h. Trim, connect and secure wiring to new Added 17.95 89.20 1601
auto re-ignition control panel and associated com- Removed -8.43 88.71 148
ponents to fit installation (Ref. Table 2-6).
Change 9.52 89.64 853
I ~I
WARNING
Added
3691) Helicopters -369D298000-523
12.48 91.51 1142
Ensure electrical connections are se- Removed -1.04 80.81 569

cured and properly insulated to pre- 105.37 573
Change 5.44
vent possibility of shorting.
i. Perform Operational Check of modified auto
2-21
"ki
Q
RELAY
K104
RELAY
K103
"~"8
00
i~s sl oo OREAR VINI INO~ 2&9~
i~toj QQ
00 RELAY
K104
O
O
RELAY lj
K304
,0/
o
AUTO
RE-IGNITIONooooO
(NOTE 2&5) o RE-IGNITION BRACKET
000 PANEL (NOTE 1&3)
O
(NOTES 1&3)
o~O O O
TERMINAL BOARD
LOWER
DNAHCTIWS
CIRCUIT
OINSIRVMEM PANEL ISLIM LINE) ASSY (TB 1000)
RELAY (K104)
BREAKER PANEL
o Mpo2wmo-n
NOTES:
~vro RrlcalrloN
L EFFECTIVE SHIPS 3690 SER IAL
NOS. 3 THRU 1149. 1151-1184
2 EFFECTIVE SHIPS 369[3 SERIAL
NOS. 1150. 1185 AND SUBS.
(WITH AUTO RE-IGNITION INSTALLED) 1.40
INDICATORSWITCH
3. CAP AND STOW WIRE ENDS. (XDS9)
d SWITCH ASSEMBLY ARRANGEMENT INSULATOR
SWITCH (S 11)
VARIES WITH HELICOPTER EFFECTIVITY. I --1 ~c0.61 (BmnlEEN SUPPORT
REPLACE EXISTING RE-IGNITION PANEL 224 8 TERMINAL 80ARD)
SUPPORT
Q
5.
WITH -23 AUTO RE-IGNITION CONTROL SIDE VIEW

REAR VIEW
ASSEMBLY USING EXISTING HARDWARE. -BAUTOREIGNITION CONTROLASSY 47-U20
Figure 2-8. Auto Re-ignition System Modification Component Locations

(Effective 369D Helicopters Only)
2-22
Q
m
ed
o
o
UNIT
P-14J ENGINE POWER OUT WARNING CONTROL
A N1TACHIN
T8502-13
L NR TACH IN
U AUTO REIGN 28 VDC OUT 0.5 AMPS
08106 B 28 VDC IN
XDSS RE-IGN r--------l C AUDIO NO. 1
i, ---1 A3 D AUDIO NO. 2
PRESS TO RESET I A2 M AUDIONO.3
G
L GROUND
%9~o c1234
____
-;---------------1 Al E
H CASEGROUND
II
-I- I
T
G NR DISABLE WHEN GROUNDED
1
I 82 8,3 J AUDIO DISABLE WHEN NOT GROUNDED
I I (81
I I IL~ I_~ F FLASHER NO. 1 "ENGINE OUT"
--------1 I B1
r
INC~f 7
rl
---1-1---
X1
-I- I-1-!-1----------!1 1 L
I
r---_--~
00
IK104
AUTO RE-IGNITION
IRELAY
~clOM
TB104
IT
59mp
1 2 I
L~Hi-t 3 4
TB502-13 rn I I I I sa30o IGNITER
-I-- --I-C-]8~C
M IGNITION
r-II B D
1\ 5 6 EXCITER
I A
1,1 ~I L---
r
t
8
L,----~L L~
r-
L io
2sVDCPOWER o O
L-------1
FROM XDS 21
TB1OW
WARNING PRESS
HOUR ROTOR OIL
TO TEST PRESS SWITCH
METER I
mVl~cH
1,~-----JI E15
Sil
82
AUTO RE-IGNITION NOTE: DASHED LINES INDICATE NEW OR
TEST REPLACED WIRES OR COMPONENTS 41-U21
vl
2-9. Auto Re-ignition Modification Wiring Diagram

Figure
t; (369D Helicopters Only)
Table 2-6. Auto Re-Ignition Wiring Data List

(effedive 3691) helicopters only)
From Termination To Termination *Material
CB106-2 MS25036-149 K104-3 M39029/5-116 22 AWG
K104-3 M39029/5-116 K104-6 M39029/5-115 22 AWG
TB1000-1 Solder TB502-13E MPCMIOM-HB 22 AWG
TB1000-2 Solder XDSS-S1-NC Solder 22 AWG
TB1000-2 Solder K104-2 M39029/5-115 22 AWG
TB1000-3 Solder XDSS-S1-C Solder 22 AWG
TB1000-3 Solder K104-5 M39029/5-115 22 AWG
TB1000-4 Solder XDS9-4 Solder 22 AWG
TB1000-5 Solder TB104-2 M39029/5-115 22 AWG
TB1000-6 Solder XDSS-1 Solder 22 AWC
TB1000-7 Solder K104-4 M39029/5-115 22 AWG
TB1000-8 Solder TB502-13A MPCM2OM-H2 22 AWG
TB1000-9 Solder E2 M525036-102 22 AWG
TB1000-9 Solder XDSS-C Solder 22 APJG
TB1000-9 Solder S11-l MS25036- 149 22 AWG
TB1000-10 Solder Sil-2 MS25036-149 22 AWG
TB1000-10 Solder K104-7 M39029/5-115 22 AWG
TB1000-IO Solder Hour Meter 3-520141-2 22 AWG
XDSS-1 Solder XDS9-2 Solder 22 AWG
XDS9-2 Solder XDS9-3 Solder 22 AWG
XDS9-3 Solder XDS9-4 Solder 22 AWG
NOTE:
Crimp both wires using M39029/5-116 socket.
2-24
CSP-100
o
ENG I NE-TO- FILTER
OILHOSE
O
PACKING
(NOTE)
UNIONI FILTER-TO- COOLER

OIL HOSE
SCAVENGE OIL FILTER

INSTALLED
PACKING
(NOTE)
PACKING
(NOTE)
VALVEPACKII I I L~ O L IN)HOSEASSY
NOTE:
REPLACEMENT PART UNION

SUPPLIED FROM PACKING
CONVERS ION KIT. /(NOTE)
HOSE ASSY
(OIL OUT)
47-1301
Figure 2-10. Oil System Hose Removal
2-25/(2-26 blank)
CS P
102
MDHS CSP-I08
Opt EQpt Manual
MDHS MODEL HELICOPTERS

and
Initial Installation Instructions
Upgraded Transmission Conversion
Model 369D, 369E, 369FF, 500N I-lelicopters
McDonnell Douglas Helicopter Systems

5000 East EncDowell Road
Mesa, Arilona 85215-9797
Issued: 2 April 1996

Revision 1: 1 May 1996
IVI FG I
INTRO
INSERT LATEST CHANGE PAGES, DESTROY SUPERSEDED PAGES

The asterisk indicates pages Changed, Added or Deleted by the Current
Change.
Date of issue for original and change pages are:
Original April 2, 1996 Revision 1 April i, 1996
Page Revision Page Revision

*Title Revision 1 SECTION 1
CR- 1A N/A 1-1 Original
CR-BB N/A *1-2 thru 1-10 Revision 1
LOEP SECTION 2
TR Original 2-1 thru 2-3 Original
*A/(B blank) Revision 1 *2-4 thru 2-6 Revision 1
TOC 2-7 and 2-8 Original
i/(ii blank) Original *2-9 Revision 1
FIGURES 2-10 and 2-11 Original
Xiii/(iv blank) Revision 1 *2-12 thru 2-14 Revision 1
FOREWORD 2-15 thru 2-25 Original
F-1/(F-2 blank) Original +2-26 thru 2-28 Revision 1
Revision 1 AI(B blank)

MCDONNELL DOUGLAS HELICOPTER SYSTEMS
TECHNICAL MANUAL RECOMMENDED CHANGE REPORT
PUBLICATIONS CHANGE REQUEST

This manu al has been prepared and distributed by the Technica 1 Publicati ons Department and is intended
for use by personnel responsible for the maintenance of MDHS 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 vour comments to this office using this form (or
a duplicate). An endeavor will be made to include such information in future changes.
Date
Originator
Address
Telephone Number Fax
Book Identification CSP- Change Number i Date
Description Area:
~A! Section Number Page Number(s)
Figure Number(s) Helicopter Model(s~
Index Number(s) Serial Number(s)
Remarks i recommendations:
Check If this is a
1
Change ct Address Check lor more cards j
PUBLICATIONS CHANGE REQUEST

This manual has been prepared and distributed by the Technical Publications Department and is intended
for by personnel responsible for the maintenance of MDHS Helicopters. Periodic revision of this
use
manua 1 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 using this Corm (or i
a duplicate). An endeavor will be made to include such information in future changes.
Date
Originator
Address
Telephone Number Fax
Book Identification CSP- Change Number i Date
Description Area:
P;TAI Section Number Page Number(s)
Figure Number(s) Helicopter Model(s)

Index Number(s) Serial Number(s)
Remarks recommendations:
Check If this is a
1 j
Change of Address Check Icr more cards I
International Mail Only CR-28

McDonnell Douglas Helicopter Systems PUBLICATION NO. CSP-102
Mesa, AZ 85215 Revision No. 1: 1 May 1996
REVISION TO
CSP-108
Initial Installation Instrmctions
for
Upgraded Transmission Conversion
Issued: 2 April 1996
Revision No. i: 1 May 1996
FILING INSTRUCTIONS:
Beforeinserting this change, ensure the manual is current.
Check the existing List of Effective Pages in the manual to ensure all prior revisions are inserted.
(Do not insert this revision if prior revisions are not inserted).
Incorporate this change by removing old pages and inserting new pages as indicated below
Remove Pages Insert Pages Remove Pages Insert Pages

Title Title Section 1
LOEP 1-1 thru 1-9/(1-10 blank) I-lthru 1-10

A/(B blank) A/(B blank) Section 2
List of Figures 2-3 thru 2-6 2-3 thru 2-6
iii/(iv blank) iii/(iv blank) 2-9 thru 2-14 2-9 thru 2-14
2-25 thru 2-28 2-25 thru 2-28

RECORD OF REVISIONS
CSP-102
MFG REV
DESCRIPTION ISSUEDATE ATPREVDA INSERTED BY
NO
Issue 4/2/96 1/30/97 ATP/ES

CSP-102 Original
1 5/1/96

MCDONNELL DOUGLAS
HELICOPTER SYSTEMS
MANUAL TITLE: CSP-O2 MAINTENANCE MANUAL
REV. DATE DATE REV. DATE DATE

NO. INSERTED BY REMOVED BY NO. INSERTED BY REMOVED BY
Original TR
CSP- 102 Opt Eqpt Manual
TABLE OF CONTENTS
Pars Title Page Para Title Page

FOREWORD 2-2. Serial Number Applicability 2-1
DESCRIPTION F-l 2-3. Reference Data 2-1
F-l. Purpose and Contents of this
2-4. Initial Preparation 2-1
Manual F-l
2-5. Equipment Removal 2-1
2-6. Canted Station 124.00 Modification 2-4
F-3. Component Mandatory
2-9. Aft Mast Base Drain Relocation 2-7
Replacement F-l
2-10. Canted Station 78.50 Modification 2-8
F-5. Related Publications F-l 2-17. Convenience Panel and Heater Duct
Modification 2-10
F-6. Literature Changes and Revisions F-l
2-22. BaffleAssembly Modification 2-14
SECTION 1
2-23. MainTransmission Build-Up 2-15
ILLUSTRATED PARTS LIST 1-1
2-24. Rotor Brake Caliper Installation 2-17
1-1. ScopeandContents 1-1
2-25. MainTransmission Installation 2-19
1-2. Group Assembly Parts List 1-1
2-26. OilCooler Blower Installation 2-21
2-27. 369F5450 Overrunning Clutch
SECTION 2 Installation 2-23
MAINTENANCE INSTRUCTIONS 2-1 2-28. Aircraft Reassembly 2-25
2-1. Scope 2-1 2-29. Expendable Materials 2-27
Original ii(ii blank)

LIST OF FIGURES
Figure Title Page
SECTION 1
Figure 1-1. Modification Kit Installation Airframe Structure Upgrade Transmission (Sheet 1 of 3) 1-2
1-1. Modification Kit Installation Airframe Structure Upgrade Transmission (Sheet 2 of 3) 1-3
Figure
Figure 1-1. Modification Kit Installation Airframe Structure Upgrade Transmission (Sheet 3 of 3) 1-4
Figure 1-2. Upgraded Main Rotor Driveline Modification Kit (Sheet 1 of 2) 1-7 1
Figure 1-2. Upgraded Main Rotor Driveline Modification Kit (Sheet 2 of 2) 1-8 1
SECTION 2
Figure 2-1. Mast Support Structure (Sheet 1 of 2) 2-2
Figure 2-1. Mast Support Structure (Sheet 2 of 2) 2-3
Figure 2-2. Canted Station 124.00 Frame Modification (Sheet 1 of 2) 2-4
2-3. Aft Mast Base Pan Drain Modification and Relocation 2-7
Figure
Figure 2-4. Canted Station 78.50 Frame Modification (Sheet 2 of 2) 2-9 1

Figure 2-5. Convenience Panel Modification 2-11
Figure 2-6. Heater Duct Installation ~Sheet 1 of 2) 2-12
Figure 2-6. Heater Duct Installation (Sheet 2 of 2) 2-13 1

2-7. 369D26541 Baffle Assembly Modification 2-14
Figure
Figure 2-8. Main Transmission Build-Up 2-16
Figure 2-9. Rotor Brake Caliper Installation 2-18
Figure 2-10. Main Transmission installation (Sheet 1 of 2) 2-19
Figure 2-10. Main Transmission Installation (Sheet 2 of 2) 2-20
2-11. Oil Cooler Blower Installation 2-22

Figure
2-12. 369F5450 Overrunning Clutch Installation 2-24
Figure
Figure 2-13. 369F5510 Main Rotor Drive Shaft Installation 2-25
Figure 2-14. Main Transmission Drive Shaft Runout Check 2-26
Figure 2-15. Baffle Assembly Modification 2-27 1
Revision 1 iii/(iv blank)

CSP-10=2 Opt Eqpt Manual Forward
FOR EM(ORD
DESCRIPTION
F-l. Purpose and Contents of this Manual At the listed finite-life hours, components or as-
This manual supplements information contained semblies must be removed from the helicopter and
in the Handbook of Maintenance Instructions permanently retired from service.
(CSP-HMI-8) and the Illustrated Parts Catalog At the listed inspection interval, the components
(CSP-IPC-4). This manual contains an Illustrated or assemblies must be inspected in accordance
Parts List (IPL) for procuring replacement parts with the Handbook of Maintenance Instructions
and instructions for initial installation of the
larg- (HMI).
er 369F5100 transmission, 369F5450 overrunning
F-4. Organization of Contents
clutch assembly and 369F5510 main rotor drive
The contents of this manual are grouped into sec-
shaft.
tions as outlined in the Table of Contents. Each
section is organized toprovide comprehensive cov-
P-2. AoplicabilitV erage of the systems, major equipment groupings
This manual is only to be used for the upgraded and major components that are similar or
transmission conversion for the 369DIEFF associated. Procedures for each of these are pres-
500N Model helicopters. For night information ented in sequence as defined in Introduction (Ref.
and characteristics, refer to applicable Pilots CSP-HMI-8).

Flight Manual. F-5. Related Publications
Reference is made throughout this CSP to CSP-
F-3. Component Mandatory Re~lacement HMI-8 and CSP-SRM-6. These manuals should
The Airworthiness Limitation Replacement be used as throughout the conversion. The

noted
Schedule (Ref Sec. 04-00-00, CSP-HMI-8) speci- Illustrated Parts Catalog (CSP-IPC-4) should be
used for ordering any replacement parts required.
fies the mandatory replacement time, structural
inspection interval and related structural inspec- F-6. Literature Changes and Revisions
tion procedures approved per the certificate basis Changes and revisions to contents of this manual
of the I~pe Certificate Data Sheet No. H3WE and are made as defined in the Introduction of CSP-
CAR 6 (6.250, 6.251). HMI-8.
Original F-1/(F-2 blank)

SECTION 1
1-1. Scape and Contents 1-2. Groun Assembly Parts List
This illustrated parts list provides, by means of The following information is provided to aid the
text (parts list) and companion illustrations, a user, by means of text and detailed illustrations,
complete parts definition of the 369F5100 trans- for parts procurement only and shall not be used
mission conversion and
applies to the Model 36911, for any other purpose. This IPC sh~uld not be
3693, 369FF and 500N helicopters manufactured used_for maintenance Dur~oses.
by McDonnell Douglas Helicopter Systems, Mesa 1-3. nlustrations
AZ.
Illustrations are provided for each group assembly
NOTE
parts list. Each illustration is exploded to the ex-
The illustrated parts list is organizedand pres- tent necessary to show parts relationship for the
ented in the same manner as the 369D/E/FF complete transmission conversion.
500N Illustrated Parts Catalog (CSP-IPC-4).
For information on use, refer to CSP-IPC-4.
Original 1-1
0 iZ f;
q 1 8 2
10
II ,7
9
jQ
a~ QU 0
7
o I ~u a
O
LJ LJ
38
+i7I:~
i~\\ I
39
40
CSP102-016-1A
Figure 1-1. Modification Kit Installation

Airframe Structure Upgrade Transmission
(Sheet 1 of 3)
1-2
Revision 1
Opt Eqpt Manual Section I
CSP-1OS
14 14
13
i II~
5-----
.=====.=*==---============i
18
j~ i I
I
III I 1 18
2=t~l _
19 I c t t
jj
!I I
15
20
O 5
29
22
21
,oC>
27
24
25
26
23
16
14
13
O
I I 17
I
II
O
14
15 O CSPI 02-01 6-2A
Figure 1-i. Modification Kit Installation

(Sheet 2 of 3)
1-3
Revision 1
~1
29(REF)
o I
O 32REF
32 REF
32
~I
7 se
o 8
CSP102-016-3A
Figure 1-1. Modification Kit Installation

(Sheet 3 of 3)
1-4 Revision 1
FIGURE SERIAL NUMBER

QTY
AND EFFECTIVITY
PART NUMBER DESCRIPTION PER
INDEX
ASSY 369DIEIFF 500N
NUMBER
1-1- 369D292300-501 Mod Kit Instl., Airframe Structure REF ALL

Upgraded XMSN With Heater
(Commercial)
369D292300-505 Mod Kit Instl., Airframe Structure REF ALL
Upgraded XMSN Without Heater
(Commercial Military)
369D292300-701 Mod Kit Instl., Airframe Structure REF ALL
Upgraded XMSN With Heater(Military)
-11369D23011-49 .Channel I 1
-2 369D292301-1 .Angle 1
-3 369D292301-2 .Angle 1
-4 NAS1738B4-4 .Rivet (QPA 15 W/O heater) 17
5 369D292301-3 .Bracket Assy 1
-6 MS20615-5M6 .Rivet 1 8
-7 369H3011-27 .Shim 1 2
-8 MS20615-4M5 .Rivet 12
-9 MS20470AD4-5 .Rivet 1 8
-10 HS5603~-4 .Pin 4
-11 HS5583-6 Collar 4
-12 MS20470AD5-5 .Rivet 1 19
-13 MS20470AD5-7 .Rivet 8
-14 MS20615-5M8 .Rivet 1 2
-15 NAS173884-1 .Rivet 20
-16 MS20470AD3-4 .Rivet 6
-17 369D23011-39 I.Fitting Assy. 1
-18 NAS1738B4-3 .Rivet 1 4
-19 369D22508-71 .Bracket (W/ heater only) 1
-20 369D22508-69 .PaneI 1
-21 369[1)26553-11 .Clip I 1
-22 3691)26553-12 .Clip I 1
-23 369D292481-1 .Splitter Duct Assy. (Commercial) 1
3690292481-3 Splitter Duct Assy.(Military) 1
-24 NAS1402-2 .Screw I 1
-25 AN960-8 .Washer 1
-26 NAS1329A08-75 .Rivnut 1
-27 MS21266-1N .Grommet AR
-28 369D392475-17 .DuctAssy. 1
29 369D292485-1 .Hose (W/ heater only) 1
-30 HS4020A3600 .Seal 1
Revision 1 1-5
FIGURE
AND QTY SERIAL NUMBER
PART NUMBER DESCRIPTION PER EFFECTIVITY
INDEX
NUMBER ASSY 369D/E/FF 500N
-31 MS35489-14 .Gromment 1
-32 H5-5100-134 .Baffle Assy 1
-33 NAS603-8 .Screw 37
-34 AN960KD10L .Washer AR
-35 H5-5100-121 .SealAssy. LH 1
-36 1-15-5100-122 .SealAssy. RH 1
-37 H5-5100-103 .Driveline Cover 1
-38 MS20470D4-4 .Rivets 4
-39 HS5604-5-2 .Pin ........._,.

2
-40 HS5614-5 .Collar 2
1-6 Revision 1
I
;Ii i
i!i
11
10 ~32 4
o~E
P^,
6
-J
0" ~8
CSP102-017-1
Figure 1-2. Upgraded Main Rotor Driveline Modification Kit

(Sheet 1 of 2)
1-7
Revision 1
1 12
1B
ai
19rr 18
4 19
O 19
19 19
18 19
O
38
30
31 29
32
20
33 3~8
23
22
34
35
36
37
24
28
25
27
26
O CSP102-017-2
Figure 1-2. Upgraded Main Rotor Driveline Modification Kit

(Sheet 2 of 2)
1-8 Revision 1
FIGURE
QTY SERIAL NUMBER
AND
INDEX
ASSY 369D/UFF 500N
NUMBER
1-2- 1369F9500-505 Upgraded Driveline Mod. Kit REF ALL

For XMSN Only
369F9500-503 Upgraded Driveline Mod. Kit (C20 Engine) REF ALL
369F9500-501 Upgraded Driveline Mod. Kit (C30 Engine) REF ALL
-1 1369F5510-1 Main Rotor Driveshaft 1
-2 369F5100-503 .Transmission Assy 1
-3 369A5516-3 .Shim AR
369A551 6-5 .Shim AR
369A551 6-7 .Shim AR
369A551 6-9 .Shim AR
-4 MS21250-08058 .Bolt 4
-5 MS20002C8 .Washer 4
-6 AN960-816L .Washer 4
-7 AN960-816 .Washer 4
-8 42FW820 .Nut 4
-9 NAS6605-11 .Bolt 4
-10 369A2033 .Washer, Special 4
-11 MS21044N5 .Nut 4
-12 147D-2 .Snubber 1
-13 NAS617-6 .Packing 1
-14 76072-15 .Pressure Switch 1
-15 NAS6606H52 .Bolt 2
-16 1 AN960-61 6LL .Washer 9
-17 HS4620C19-29 .Bushing 2
-18 369D21010-3 .Eyebolt (UseNV 369F5510-1) 3
-19 HS579&4-26 .Bolt 7
-20 NAS6604H8 .Bolt 4
-21 NAS6604H7 .Bolt 2
-22 NAS6604H6 .Bolt 2
-23 369F5193-1 .Shim 1
-24 1369F513&1 Pulley Guard 1
-25 369F5137-1 .Pulley Driver 1
-26 369F5155-1 .Input Coupling Shim 1
-27 369F5160-1 .Input Bolt 1
-28 3691=5133-1 .Input Coupling 1
-29 369F5190-1 .Oil Cooler Fan Bracket 1
-30 MS51957-42 .Screw (UseNV 369F5450-501) 3
Revision 1 1-9
FIGURE
QTY SERIAL NUMBER
AND
INDEX
ASSY 369D/UFF 500N
NUMBER
1-2-31 NAS620A8L Washer (UseNV 369F5450-501) 3
-32 369F5467-1 .Seal Assy (UseNV 369F5510-1) 1
-33 369F5450-501 .Clutch Assembly 1
-34 369F5468-1 .Bolt (C20 Engine) 1
-35 369F5469-1 .Bolt (C30 Engine) 1
-36 M83248/1-019 .Packing (UseNV 369F5450-501) 1
-37 M83248/1-206 .Packing (UseNV 369F5450-501) 1
-38 NAS6604-5 .Bolt (QPA of 4 on 369F95000-505) 8
1-10 Revision 1
SECTION 2
2-1. Scope a. Main rotor blades (Ref. Sec. 62-10-00).
This section provides information for the conver-
b. Main rotor drive shaft (Ref. Sec. 63-10-00).
sion of the 369DIEFF 500N Model helicopters to
thelarger 369F5100 transmission, 369F5450 over- c_ Main rotor hub (Ref. Sec. 62-20-00).
running clutch assembly and 369F5510 main rotor
d_ Main rotor swashplate and mixer assembly
drive shaft. When modifying the helicopter to the
(Ref. Sec. 62-30-00).
larger 369F5100 transmission, it is recommended,
but not required, to convert to the larger overrun- Intake
e_ fairings (Ref Sec. 53-30-00 or
ning clutch and main rotor drive shaft at the same 53-30-30).
time.
f- Anti-torque drive shaft access screen under
The tasks in this section are arranged in a logical
intake fairings (Ref. Sec. 52-50-00).
order in which they should be accomplished.
2-2. Serial Number g, Anti-torque flight controls from upper deck

(Ref. Sec. 67-20-10 or 67-20-30).
According to helicopter serial number (S/N), not
all tasks may need to be performed. Tasks that do h, All interior trim and insulation from cargo
not have a S/N in the title pertain to all helicop- compartment (Ref. Sec. 25-30-00).
ters. Tasks that have a S/N in the title pertain to
i. Tunnel-routed control tubes (Ref. Sec.
only those helicopters. 67-10-00).
2-3. Reference Data
it Sta 124.00 bulkhead panels (Ref. Sec.
When performing the following procedures, refer
25-30-00).
to the appropriate maintenance manual. All refer-
ences are to the Handbook of Maintenance k. Main transmission drive shaft (Ref. Sec.
Instructions (CSP-HMI-8) unless stated other- 63-10-00).
wise.
I, Oil cooler blower (Ref. Sec. 63-21-00).
2-4.
m. Overrunning clutch assembly (Ref. Sec.
Prepare the aircraft for conversion as follows:
63-10-00).
a Identify all components, including attaching n. Engine and attaching hardware (Ref. Sec.
hardware, and components removed for access to 71-00-00 or 71-00-30).
work areas. Protect components from damage and
contamination until installed, o, Tail rotor assembly (369D/E/FF) (Ref. Sec.
64-20-00).
b- Turn off all electrical power and disconnect
battery. B Tail rotor gearbox and drive shaft (369DIEFF)
(Ref Sec. 63-15-10).
2-5. E4uiDment Removal
Refer to CSP-HMI-2 for detailed removal proce- qz Tail rotor control rod assembly (369D/E/FF)
dures; remove the following items: (Ref. Sec. 67-20-10).
r, Horizontal and vertical stabilizers (Ref. Sec.

53-50-10 or 53-50-30).
s, Tailboom assembly (Ref. Sec. 53-40-00 or

a The following parts are to be removed from the 53-40-30).
helicopter for access to work areas and to remove
weight to prevent possible airframe warpage. Heater ducting from around transmission as-
a Do not the mast base, this will assist in

sembly compartment area (ifinstalled) (Ref. Sec.
remove
21-40-00).
keeping the airframe rigid.
u, Rotor brake, if installed (Ref. Sec. 63-22-00).
NOTE
If helicopter is
v, Maintransmission(Ref. Sec.63-20-00).
equipped with Bendix couplings
or main transmission drive shaft, it must be con- w_ Anti-ice cable assembly (if equipped with a
verted to Kamatic couplings and drive shaft. 250-C20B engine) (Ref. Sec. 75-10-00).
Original 2-1
I 6 1ii1. 45 4
1plj.6k o1~
io 9
-r
5
JJ4 5
I
L~o 13 1
Y~
.,43
20
39 38 29 34
13
.YL-~ i
40
26 35
30
36 LL~ 5
q~19
24
21
23
~18
28
3~16
6
i P
27_C---~ 12
21
\r
33
15
17
21
15
37 9
i O~i3
31B
45
~8\
11 I\
2
2 44
32
j/f
56-031-1
Figure 2-1. Mast Support Structure (Sheet 1 of 2)
2-2
Original
2~9r I
i
ii 1 i22
,f
2-;1~5
-I,
s
1 MS20615M5 Rivet 26369313011-13 Channel
2 MS20470AD3 Rivet 27 369H3011-37 Angle

3 MS20615M3 Rivet 28 369H3011-39 Angle
4 MS20426AD4 Rivet 29 369H3011-15 Channel
5 MS20427M5 Rivet 30 369H3011-17 Channel
6 MS20470AD5 Rivet 31369H3011-19 Panel,LH
7 MS20470AD4 Rivet 3691-13011-21 Panel,RH
8 MS20426AD5 Rivet 32 369113011-23 Panel, LH
9 MS20426AD3 Rivet 369H3011-24 Panel,RH
10369D23011-13 Panel 33369113011-33 Clip
11 NAS697A3 Nutplate 34 MS20470A4 Rivet or
12369D23011-31 Pan MS20470AD4 Rivet
13 MS21075L3 Nutplate 35 AN960PD6L Washeror

AN960PD4 Washer
14 NAS1465-2 Pin
15 NAS1465-3 Pin 36 TC814 Strap or
16 NAS1465-4 Pin
SSCBM Strap
37 NAS557-4 Grommet
17 NAS1425-3 Pin
38 369113011-29 Shim
18 NAS1466-3 Pin
39 369H3011-27 Shim
19 NAS1466-4 Pin
Pin 40369H3011-25 Shim
20 NAS1426-3
21NAS1080-5 Collar 413691123011-11 FittingAssy
22 NAS1080C5 Collar 42 3691123011-21 FittingAssy
23 NAS1080-6 Collar 43 369H23011-33 Angle
24 NAS1080C6 Collar 44 369H23011-5 Angle
25 369113003-1 Fitting, LH 45 3691123011-3 Angle, LH
369113003-2 Fitting,RH 3691-123011-3 Angle, LH
Figure 2-1. Mast Support Structure (Sheet 2 of 2)
2-3
Original
2-6. Canted Station 124.00 Modification NOTE
The 500N3000-29 clip will be re-used when

Expendable Materials
installing the new channel.
Refer to Table 2-1
Nomenclature Item
f, Carefully slide 369113011-15 channel forward
and out.
Primer 3
NOTE
Primer (epoxy) 10 1 Helicopters may have either a 389Da300s-5,
-15 or 369D23009-13 frame.
2-7. Frame Rework
(Ref. Figure 2-2) gL MOdifST 369D23008-5, -15 (or 369D23009-13)
frame as follows:
NOTE
There are different part number frames that

CAUTION
may be installed in the aircraft (369D23008-5,
-15 or 369D23009-13).
When marking the frame, ensure that cut-lines
a. Remove(4)MS20615M5 and(l9) will have proper edge distance from existing riv-
MS20470AD5 rivets from 369113011-15 channel et holes that are to remain.
common to 369D23011-13 panel.
i. Measure 2.33 inches (59.2 mm) from outsides
b, Remove (26) MS20470AD4 rivets from
of frame and mark for cut.
369113011-15 channel common to 369D23008-5
frame.
c. Remove(4) NAS1466-4 lockbolts from sides of CAUTION

369H3011-15 channel.
d Remove (4) MS20615M5 rivets from bottom of

Always protect surrounding components from
369113011-15 channel common to 3691-13003 mast damage. Major damage can occur if precautions
are not taken.
support.
For 500N Model helicopters only, carefully drill 2 Slide a thin piece of stainless sheet between
out rivets securing 500N3000-29 clip and remove. frame and 3691123011-13 panel.
2x3000 /:i\
i ~2x2.331NCHES BL
0.00
MATERIAL TO BE
REMOVED
i/
TRIM LINE
REWORK OF 389023088-5. -15

OR 369[)23009-13 FRAME
CSP102-003-1
Figure 2-2. Canted Station 124.00 Frame Modification (Sheet 1 of 2)
2-4 Revision 1
MS20615-5M6 MS20470AD5-5 MS20615-5M6

RIVETS RIVETS RIVETS
ii-l ;;;;;;;-i :......L.:::I;..
j= -i*"__-I=-;-_=;---~-r ii~.
369023011-13 PANEL
TOP VIEW
LOOKING DOWN
BL
6X MS20615-4M RIVET
369023011-13 0.00
PANEL (NOTE 2)
369D292301-2ANGLE
~R
(LOCATE APPROX. AS SHOWN) 369D23011-49
8
0.45 CHANNEL
0.28
HS5603-6 PIN
MS5583-6
369H3003-2
FITTING
9 i
.l......~...i ~r.,e
O
(NOTE 4)
COL AR369H30 3-1
FITTING
MS20470AD4-5 RIVET
:C (NOTE 3) MS20615-5M6 RIVET
NOTE 1 :i~ i~ (NOTE 2)
369[3292301-1 ANGLE
L (LOCATE APPROX. AS SHOWN)

369023008-20
FRAME 369023008-19
FRAME
o o
CANTED STATION 124.00

VIEW LOOKING AFT
MS20470AD4-4 RIVETS
(PICK UP MISTING RIVET HOLES
UPON REINSTALLATION)
+lii
NOTES:
NOTE 6 HS5604-5-2 PIN
1. 389H3011-27SHIMAS REQUIRED, 0.040MAX.
HS5614-5 COLLAR
2. PICKUPE(ISTING RIVETLOCATIONS.
3. PICKUPEXISTING PILOTHOLES. BRACKETREMOVAL
4. 0.189-0.191 HOLEIN 369D23011-49CHANNEL ~il (500N MODELS ONLY)
TO MATCH MAST SUPPORT.
5. ALLDIMENSIONSIN INCHES.
6. ON 500NMODELSONLY, REMOVETHISBRACKET
FOR EASE OF REMOVING CHANNEL; REINSTALL
BRACKET AFTER NMI CHANNEL IS INSTALLED. CSP102-003-2A
Revision 1 2-5
3. Usingextremecare, cutframealongmark i Back drill and cleco (23) #20 holes from panel
with acutting disc. through top flange of channel.
4. Deburr cuts and touch up with primer (3, NOTE
Table 2-1).
A maximum of 0.040-in. (1.0 mm) shims are al-
2-8. 369D23011-49 Channel Installation lowed between channel and 369B3003-1 and -2
(Ref. Figure 2-2) fittings.
NOTE g, Install shims, as required, between bottom of
channel and 3691-13003-1 and -2 fittings.
a When locating the 369D23011-49 channel, en-
sure channel,
edge distance is equal on both sides h. Back drill (4) #20 holes from the -1 and -2 fit-
and channel is positioned firmly against tings through bottom flange (outboard ends) of
369D23011-5 frame and 369D23011-13 panel, channel.
Install all rivets wet using epoxy primer (10). i Back drill and cleco (4) 0.189-0.191 inch holes
from mast support in outboard ends of channel.
a Locate and secure 369D23011-49 channel in
placeon forward side of 3691323008-19 and -20 i, Deburr holes and touch up with primer (4).
frames.
ii, Install (4) MS20615-5M6 rivets from panel
B Reinstall 500N3000-29 clip as follows: through top flange (outboard ends) of channel.
i. Using existing rivet holes on common to clip L, Install (19) MS20470AD5-5 rivets from panel
and 500N3000-35 channel. through top flange of channel.
2. Using -29 clip holes, drill two 0.3085 0.3105 m. Install (4) MS20615-5M6 rivets from
through clip and -49 channel. 369H3003-1 and -2 fittings through shims into bot-
tom flange (outboard ends) of channel.
3. Install two HS5604-5-2 pins with HS5614-5
collars. n. Install(4) HS5603-6 pins and HS5583-6 col-
lars through outboard ends of channel and mast
c. Backdrillandcleco (12)#30holesfromframe
support.
through channel.
o. Install(8) MS20470AD4-5 rivets through
d. Locate and secure 369D292301-1 and -2
369D292301-1 and -2 angles and frame.
angles in place on aft side of 369D23008-19 and
-20 frames. B Install(12) MS20615M4-5 rivets through
angles, frame and channel.
e. Using pilot
holes in -1 and -2 angles, drill and
cleco (8) #30 holes through channel, q, Touchuprework areawithprimer(4).
2-6 Revision 1
2-9. Aft Mast Base Drain Relocation e, Trim aft side drain nange as shown with a 0.13
(Ref. Figure 2-3) The aft mast base drain must be radius at each end of cut.
moved outboard and aft for clearance when instal-
fL Using forward rivet holes in drain flange, drill
ling the larger transmission.
and cleco (2) #40 holes in pan.
Expendable Materials gS Using existing aft-outboard rivet hole in pan,

Refer to Table 2-1 drill and cleco (1) #40 hole in drain flange.
Nomenclature Item ht Locate and drill remaining #40 hole through

drainflange and pan, 0.50-in. (12.7 mm) outboard
Sealing compound 2 and 0.18-in. (4.6 mm) aft of drain hole.
Primer 10 k Drill 0.250-in. hole in pan to match drain.

(epoxy)
ir Remove drain.
Acrylic lacquer 14
k, Deburr pan and drain, and touch up with paint
a, Remove (4) MS20470AD3 rivets securing drain (14, Table 2-1) as required.
to mast base pan.
NOTE
b, Remove sealant from around drain and remove Install all rivets wet using epoxy primer (10).
drain.
i, Apply a thin coat of sealant (3) to drain flange
c, Thoroughly clean remaining sealant from pan
and install drain using (4) MS20470AD3-4 rivets.
and drain.
m. Clean excess sealant from center hole of drain
d- From center of drain hole, mark pan 0.90-in.
and outside offlange.
(22.9 mm) outboard and 0.20-in. (5.1 mm) aft for
new drain hole. n. Seal all existing rivet holes with sealant (2).
0.50 --r~ I- 020

MISTING RIVETS
NOTES
NOTEP
PAN NOTES
R 0.13
NOTES2X 0.250 HOLE
0.90
0.50
MS20470AD3-4 RIVETS
(NOTE 4)
#40 HOLE
MS20470AD3-4 RIVET
iiYor
NOTES:
PAN
ALL DIMENSIONS IN INCHES.
MS20470ADS-4 RIVET. PICK UP MISTING RIVET LOCATION.
3. FILL MISTING HOLES WITH SEALANT (3, TABLE 201, 91-00-00).
4. PICK UP MISTING RIVET LOCATIONS IN DRAIN FITTING. CSP102-005
Figure 2-3. Aft Mast Base Pan Drain Modif~cation and Relocation
Original 2-7
2-10. Canted Station 78.50 Modification b. Slide fitting through hole in 369D22508-7 web
(Ref. Figure 2-4) and remove,
c, Fill existing holes with sealant (2, Table 2-1),

Expendable Materials 2-12. 3691322508-7 Web Modification
Refer to Table 2-1
a, Remove (6) MS20470AD4 rivets from
Nomenclature Item 369112508-303 bracket; remove bracket.
Sealing compound 2 121 Remove hardware connecting heater duct to

3691-12508-297 bracket (if equipped with heater
Primer (epoxy) 10 system).
Acrylic lacquer 14 c, Remove (3) MS20470AD4 rivets from
369H2508-297 bracket; remove bracket,
i, Mark web for cutout ensuring correct corner

2-11. Forward Mast Base Drain Removal radius,
e- Cut out and deburr web,

a, Remove (2) MS20470AD3 rivets from drain
common to mast base pan, f, Touch up edges with paint (14).
NOTEP
6X R 0.25 7 Jt------ 7.80 -----------Ccl.BB
1 mo.ss 0.10
2X 0.97
2X 2.30
2X R 0.38
2X19"
I I,
369H2508-303 BRACKET
969H2508-297 BRACKET
(REMOVE) (REMOVE)
369D22508-7 WEB
0.11
NOTES:
1. ALLDIMENSIONS ININCHES.
INTERSECTION UNE BETWEEN 369D23011-31 PAN AND 369[)22508-7 WEB.
3. PICKUP MISTINGRIVET LOCATIONS.
4. FILL MISTING HOLES WITH SEALANT (3, TABLE 201, 91-00-00).
5. FILLGAPAROUND TUBEWITH SEALANTS 13).
8. LOCATE VERTICALLY WITH EQUAL DISTANCE ON BOTH SIDES AND/OR TO
ELIMINATE INTERFERENCE WITH MISTING RIVET HEADS.
CSP102-004-1
2-8
Original
DIA 0.250 HOLE IN 369023011-31

NOTEB
PAN TO MATCH 3691)23011-39
369H3011-37
2.64 ---1 FITnNGASSEMBLY
8x MS20470AD5-7 RIVET
(NOTE 3)
0.16 -I I MS20470AD3-4
2xMS20615-5M8 RIVET
RIVET
FORWARD MAST
lb I BABE DRAIN
I; +I ~I
NAS1738B4RIVET 369[)23011-31
y
NAS173884 RIVET
NOTE5
20x NAS173884 RIVET MS20470AD3-4 360[)22508-69

RIVET PANEL
369D22508-7
WEB VIEW LOOKING UP
8X MS20470AD5
O
a.oo
NOTE 5
RIVET
I i
I
NAS1738B4-3 RIVET 1~
(NOTE3) "!I
1 II -e j NAS1738B4-3 RIVET
Ii (NOTE 3)
369[)22508-71 BRACKET
I
(WITH HEATER ONLY)
jj 2.95
0.50
5XNAS1738B4-4RIVET
(NOTEI)
4.70
NAS1738B4-4 RIVET /1 0.38

(NOTE 3)
0.40
3691)22508-69 20XNAS1738B4-1
369D292301-3 BRACKET
PANEL RIVET
(NOTE 6)
369D22508-7
PANEL
CSP102-004-2
Revision 1 2-9
2-13. 3691[)22508-69 Panel Installation NOTE
a. Insert 369D22508-69 panel into 369D22508-7 Install all rivets wet using epoxy primer (10).
web from the aft side.
c. Install(B) NAS1738B4-4rivets.
b, Positionpanel vertically against the mast base
a Reinstall hardware connecting heater duct to
pan and equally side-to-side,
369D22508-71 bracket (if equipped with heater
Back drill and cleco (4) #30 holes through system).
edges of panel.
2-16. 369D292301-3Bracket Installation
d- Drill and cleco (20) #30 holes along bottom and
sides ofpanel, a Positionbracketon -7webverticallywith
equal distance on both sides and/or to eliminate in-
e, Back drill and cleco (10) #20 holes along top of terference with existing rivets.
panel.
hl Back drill and cleco (5) #30 holes,
NOTE
NOTE
Install all rivets wet using epoxy primer (10)
Install all rivets wet using epoxy primer (10).
i Install (4) NAS1738B4-3 rivets in holes on
outboard edges of panel. E Install (5) NAS1738B4-4 rivets.
gL Install (20) NAS1738B4-1 rivets in holes com- 2-17. Convenience Panel and Heater Duct
mon to panel and web. Modification
(Ref. Figure 2-5 and Figure 2-6) The following
h- Install (2) MS20615-5M8 rivets in holes at top
procedure is only for helicopters equipped with a
on outboard edges of panel.
heater system.
i Install (8) MS20470AD5-7 rivets in holes at
top of panel common to pan. Expendable Materials
Refer to Table 2-1
2-14. Forward Mast Base Drain Installation
Nomenclature Item
a, Locate drain on mast base pan so tube pro-
trudes through hole in 369D22508-69 panel. I Tape,pressuresensitive 1 5
b_ Mark and drill 0.250-in. hole in pan to match

Adhesive 7
drain.
Adhesive (epoxy) 8
c. Usingdrainasapattern, drillandcleco(~)#dO
rivet holes.
Primer (epoxy) 10
ii, Remove drain,

Lockwire 11
e, Deburr and touch up drain and pan with paint
(14). Acrylic lacquer 14
NOTE
2-18. Heater Component Removal
Install all rivets wet using epoxy primer (10)
a. Remove hardware securing 369D292475-13 (or
f, Apply a thin layer of sealant (2) to drain flange -15) duct assembly to 3693~22508-71 bracket.
and install using (2) MS20470AD3-4 rivets.
b, Remove clamps attaching duct to 369D292490
g, Clean excess sealant from center hole of drain and 36933292503 hoses and remove duct.
and outside of flange.
c. Remove clamp connecting 369D292503 hose to
h, Fill gap around drain tube, where tube pro- heating valve on convenience panel and remove
trudes through panel with sealant (2), hose.
2-15. 3691322508-71 Bracket Installation d, Remove conveniencepanel.

a, Position bracket on -7 web vertically with e- Slidesplitterductup andfreefromvertical
equal distance on both sides and/or to eliminate in- duct assemblies and remove.
terference with existing rivets.

fi Remove all components from convenience pan-
Back drill and cleco (2) #30 holes, el.
2-10 Original
2-19. Convenience Panel Modification d. Deburr and install NAS1738B4-4 rivets.
NOTE 2-21. Heater Component Reinstallation

Ensure proper corner radius when trimming a. Position new splitter duct in place; trim length,
convenience panel and 369D26553-5 bracket. as required, for proper fit into 369D292478 ducts.
Mark and trim b. Reinstall components previously removed from

a. panel, bracket and isolator
mount as shown. convenience panel.
b. Cutgrommetto size.
c. Using new mounting holes, reinstall conve-
nience panel using existing hardware.
c, UsingAdhesive (7, Table 2-1) bond grommet to
d. Install 369D292480-17 elbow on splitter duct;
panel.
bond elbow to splitter duct with adhesive (8).
i. Touchupedgeswithpaint (14).
e. Connect 369D292503 hose to heater valve us-
2-20. 369D26553-11 and -12 Clip Installation i"g existing hardware.

f, Install 369D292485-1 hose using existing
a. Remove existing 369D26553-11 and -12 clips
from and scrap. hardware; attach to elbow using lockwire 0.032
panel
(11).
b. Locate 369D26553-11 and -12 clips, supplied
with kit, and position vertically to achieve equal g, Install 369D292475-17 duct between -1 hose
and 369H92475-71 duct assembly.
edge distance on both ends and/or to eliminate in-
terference with existing rivets. 1. Using existing hardware to mount -17 duct to
369D22508-71 bracket, tighten nut until duct is
c, Drill (5) #30 holes in each clip and cleco in
snug against mounting bracket.
place.
2. After the 369D292485-17 and 3691192475-71
NOTE
ducts are assembled, seal the joint by wrapping
Install all rivets wet using epoxy primer (10). with black 471 plastic friction tape (5).
PANEL
PANU
ASSEMBLY
BRACKET ASSE~BLY BRACKET
ASSE,MBLY ASSEh?BLY
BRACKET
ASSEMBLY
:i
3.45 3.45
O
(C~ 1
OJ____ &O
~o>)l y~R0.12
R 0.13
MS21266-1N GROMMET
0.25 (NOTE 2)
VIEW A-A
2. CUTTO REQUIREDLENGTH. CSP102-006
Figure 2-5. Convenience Panel Modification
Original 2-11
REINSTALL MISTING HARDWARE

NAS1303-30 BOLT
SL210-3-2 CUPNUT
AN960KD1 OL WASHER
(UNDER BOLT HEAD)
HS306-323WASHER
(UNDER NUT)
(NOTE 1) 7e.so
e e -(5
3698292475-17
LOCKWIRE
369[)292485-1
HOSE
j 369[)292503 (NOTE 2)
HOSE (NOTE
/i 2)
K 369[)292480-17
ELBOW
i (NOTEI)
j AEWORKE0369MB55S
PANELASSEMBLY
REINSTALL
EXISTING HARDWARE
4X NAS1402-4 SCREW
.ii
KOTES:
1. TORQUE NUT UNTIL DUCT SUPPORT IS SNUGLY CLAMPED BEMIEEN BOLT HEAD AND BRACKET.
2. REINSTALLHOSEUSING MISTINGCLAMPS.
3. AFTER INSTALLATION, BOND ELBOW TO DUCT USING ADHESIVE (117 TABLE 201, 91-00-00).
4. AFTER 369H92475 AND 3691)292475 DUCTS ARE ASSEMBLED, SEAL JOINTS BY WRAPPING WITH
BLACK 471 PLASTIC FRICTION TAPE (32).
5. TRIM SPLITTER DUCT LENGTH, AS REQUIRED, FOR PROPER FIT.
7. PICKUP MISTING RIVETLOCATIONS.
CSP102-007-1A
Figure 2-6. Heater Duct Installation (Sheet 1 of 2)
2-12 Revision 1
CSP-108 Opt EQPt Manual Section 2
369[)292485-1
HOSE
369D22508-77
369[3292503
BRACKET
HOSE
NAS1738B43
RIVET
369[)26553-12
3680292175-17 ~i CUP (NOTE 7)
DUCT NAS1738B4-3
I 11. III RIVET
O O
IrC~- 025
CONVENIENCE
NAS1402-2SCRMr II. I I\ .II PANEL
AN960-8 WASHER
NAS1329A08-75 RIVNUT 3.40
SPUTTER DICT
(NOTE 5)
NOTE5
369D292478-1 I I 111 369[)292478-2

DUCT II I I I Ci-l~ DUCT
CSP102-007-2A
Figure 2-6. Heater Duct Installation (Sheet 2 of 2)
Revision 1 2-13
2-22. Baffle Assembllv Modification 1. Measure and mark 0.20-in, (5.1 mm) around
(Ref. Figure 2-7) The upper baffle must be modi- inside of baffleas indicated: trim baffle.
fled for clearance when installing the 369F5100

transmission.
2, Markandtrimcornersea1 andtabfromside
of panel,
3. Measure3,l0inches (78,7mm)fromtopof
Refer to Table 2-1 baffle and mark; trim baffle.
Nomenclature Item 4. Deburr alltrimmed areas.
Epoxy cement 13 5, Touch up trimmed edges with paint (14, Table

2-1),
Acrylic lacquer 14
d, Cut new seal (HS4020A3600 or equivalent) to

a. Remove 369D26541 baffle from helicopter. required length,
b, Removesealsfromareas ofbaffleassemblyto e. Bond seals to baffle with cement (13).
be modified,
f, Re-identify baffle as 369D26541-33.
c, Trim baffle to dimensional requirements as
follows: $r Reinstall baffle in helicopter.
SEAL (NM3
(NOTr 1)
t
re
TRIM LINE
SEAL (NM3
R 4.96
(NOTr 1)
NOTEO
TAIM UNE
r/
BAFFLE ASSEMBLY REWORK

1
NOTE2
~LPIES:
1. HS4020A3600 MTRUSION. OR EPUIVALENT.
CUT TO REQUIRED LENGTH ON INSTALLATION.
2. MATERIALTO BE REMOVED,
CSP102-008A
Figure 2-7. 369D26541 Baffle Assembly Modification
2-14 Revision 1
2-23. Main Transmission Build-Up c- Coat coupling splines with grease (4, Table
(Ref. Figure 2-8) Perform the following steps, as 2-1) and coat bolt threads with anti-seize com-
applicable, to build up the main transmission pounds (6) before assembly.
prior to installation. d, Install shaft coupling and temporarily tighten
coupling bolt to approximately 250 inch-pounds.
Refer to Table 2-1 NOTE
Nomenclature Item If rotor brake is installed, ensure electrical re-
ceptacle the tachometer generator is clocked

on
Solvent, dry cleaning 1
to the 11 oclock position.
Sealant 2
e- Install tachometer generator with new gasket
Grease 4
(Ref. Sec. 95-30-00, Tachometer Generator Re-
Anti-seize compound 6 placement).
Cement 9 f, Install input shaft seal drain connector, bond-
ing it in place with sealant (2).
Lockwire 11
NOTE
a. If rotor brake is to be installed, proceed as fol-
On the 369F5100 transmission, the oil pressure
lows:
switch is mounted on the bottom, right side, fac-
i. Position brake disc on drivecoupling with ing down.

raised center side of disc seated f~rmly on shoulder
g, Install 147D-2 snubber, with new O-ring, and
of coupling with bolt holes aligned.
torque to 155 165 inch-pounds.
2. Insert four bolts through dise and coupling
h- Using a new O-ring, install oil pressure switch
flange; install washers and nuts on bolts. Torque
and safety with lockwire (11).
nuts, in alternating sequence, to 100 140 inch-
pounds plus drag torque. i Clean main rotor output O-ring surface with a
clean absorbent cloth dampened with solvent (1).

b- Install one preliminary 0.010 inch shim on out-
put shaft to prevent coupling bolt from bottoming in it Bond main rotor output shaft O-ring in place
shaft, with cement (9).
Original 2-15
OUTPUT
OUTPUT
COUPLING
PINION
ROTOR
BRA~KE ANTI-TORQUE
OIL FILLER \n I DRIVESHAFT
icn
LJ
OIL COOLER
BLOWER
COUPUNGBOLT
CHIP
DETECTORS
DRIVE PULLN
B B
INPUT
ENGINE-TO-TRANSMISSION
COUPLING
DRIVE SHAFT
147D-2SNUBBER
NAS617-6 PACKING
369H4551 TACH GENERATOR
(76072-15 PRESSURE SWITCH)
MS20495-C32 WIRE, LOCK
Q~d
369A7719
JUMPER ASSEMBLY
VIEW B-8
LOOKING UP
VIEW A-A
LOOKING FORWARD
CSP102-009
Figure 2-8. Main Transmission Build-Up
2-18
Original
CSP- 102 Opt Eqpt Manual Section 2
2-24. Rotor Brake Cali~er Installation

(Ref. Figure 2-9) The following procedure is for CAUTION
installation of the rotor brake caliper assembly.
The caliper assembly should be installed on the To optimum brake operation and mini-
ensure
transmission before the transmission is installed mite equipment damage, caliper-to-disc clear-
in the helicopter, ances on both sides ofdisc should be equal, or as
nearly equal as possible. Clearance adjustment

Expendable Materials is accomplished by varying number of shim
Refer to Table 2-1 washers (0.032 inch thick) placed between the
Nomenclature Item I caliper assembly and transmission.

c, Measure brake caliper housing-to-disc clear-
Lockwire 11
ances on both sides of disc with a feeler gage. If
Thread sealant 12 clearances are equal within 0.032 inch, torque at-
taching bolts to 160 190 inch-pounds and se-
NOTE cure with lockwire (11, Table 2-1).
a AN960-616LLwashers areto beusedforadjust- NOTE

ing caliper-to-disc clearance.
Clearance differences greater than 0.032 inch
Nine washers are used on each attaching bolt; can be reduced by re-arranging washers on cali-
those not used as shims should be placed under per attach bolts.
bolt heads. Washer distribution should be the
for both bolts.
d- To adjust clearances, hold caliper assembly
same
and unscrew bolts from mounting bracket. Trans-
Insert two NAS6606H52 bolts with pose washers on bolts as required. Reassemble
a. equal num-
ber of washers through the caliper (washers can be parts and recheck clearances.
on either side of caliper as needed) and install two NOTE
HS4620C19-29 bushings.
If new caliper assembly was installed or if hy-
NOTE draulic fittings were removed from old unit, coat
On the 369F5100 the brake cali- all but first two threads of two bleed screws, tees
transmission,
and plugs with thread sealant (12) or equivalent.
per bolts directly to the transmission. The brack-
et used to mount the caliper on the old transmis- e_ plugs and tees in caliper assembly,
Install
sion will not be used. screw adapters on tees and install bleed screws in
dise and
adapters.
b- Mount the caliper assembly over
thread bolts into transmission. f, Connect tube assemblies and tee units to tees.
Original 2-17
AN960-616LL
CALIPER MOUNTING BOSS
WASHER
ON TRANSMISSION
(NOTE 1)
HS4620C19-29 I AN960-616LL
BUSHING i WASHER
(NOTE 1)
NAS6606H52
BOLT
(NOTE 3)
j CALIPER
I I I 1 11\11 1 ASSEMBLY
O o18e DISC
CALIPER
CALIPER
ri~lT
NOTES:
NOTE 2
1. CLEARANCETO BEADJUSTED BYVARYING WASHERS FROM
EITHER SIDE OF CALIPER ASSEMBLY.
2. CLEARANCE TO BE EQUAL WITHIN 0.032 INCH.
3. TORPUETO 160-190 INCH POUNDS AND SAFEPIWITH
LOCKWIRE (I5D,TABLE 201, 91-00-00).
CSP102-010
Figure 2-9. Rotor Brake Caliper Installation
2-18
Original
2-25. Main Transmission Installation 5. If gap exists, remove nut and replace with
(Ref. Figure 2-10) new self-locking nut, and repeat above steps.
studs must t2, Remove main rotor mast bolts.

a. The main transmission mounting
be replaced with bolts.Replace studs as follows: install
c- Using existing washers,
M821250-08058 bolts in mast support holes.
CAUTION B d, Using a clean absorbent cloth, clean pan be-

neath main rotor mast support, especially area con-
tacted by O-ring on top of transmission.
The main transmission mounting studs are left-
handed, do not attempt to turn in the wrong NOTE
direction.
The following procedure will require the assis-
i. Remove left-handed main transmission tance of another person.
mounting studs from mast support structure pan

e- With assistance, slowly and evenly lift and
and mast base,
position transmission in place on mount bolts.
2. Remove left-handed nuts from mast base and ft Install new HS262-820 nuts with existing
install MS21044N5 nuts using original special washers.Torque nuts to 700 820 inch-pounds
washers. plus drag torque.
3. Install NAS6605-l1 bolts and torque to 160 gz Drain any residual preservative oil. Service
transmission with 14.0 pints of Mobil SHC 626 oil.
190 inch-pounds plus drag torque,
4. 0.0010-0.0015 inch feeler gage, check
h- Connect wiring to tachometer generator, both
Using a
detectors and oil pressure switch.
chip
for gap between self-locking nut and special wash-
ers. No gap allowed. i If installed, connect rotor brake lines to caliper.
A~ TRANSMISSION ASSEMBLY
A
17
~11821250-08058
MAST BASE
BOLT
MS21044N5
NUT
NAS8905-12 BOLT
(NOTEI)~ II ~pp L1 _~
MASTBASEPAN
TRANSMISSION
HS262-820NUT
(NOTE 2)
VIEW A-A
NOTES:
i. TORQUE BOLT TO 160-190 INCH-POUNDS PLUS DRAG TORQUE.
2. TORQUE NUT TO 700-820 INCH POUNDS PLUS DRAG TORQUE. CSP102-011
Figure 2-10. Main Transmission Installation (Sheet 1 of 2)
2-19
Original
Section 2
MAIN ROTOR DRIVE SHAFT
MAST BASE
COUPLING
COUPLING BOLT
(KAMATIC)
ii LAMINATED
SHIM
1 o
TAIL ROTOR
OUTPUT O DRIVESHAFT
SHAFT
OUTPUT SHAFT
DEBRIS
COVER
COOLING BLOWER
i B~A ~O
FILLER
INPUT
O-RING
SHAFT
f
PULLEY
COUPLING
(NOTE)
GUARD
PULLEY
INTERNAL
WRENCHING BOLT
G63-2032
Figure 2-10. Main Transmission Installation (Sheet 2 of 2)
2-20
Original
2-26. Oil Cooler Blower Installation g, Torque bolts to 65 75 inch-pounds and

(Ref. Figure 2-11) safety with lockwire (11).
Refer to Table 2-1
Nomenclature Item In the following step, do not use levers or other
Sealant 2 I tools on belt, or in any way force belt onto pulley.
Grease 4 h, Slide 369F5137 driver pulley onto transmis-

sion input shaft to engage belt in teeth of both pul-
Anti-seize compound 6
leys.
Loc~wire 11
a. Remove 369D25627 oil cooler fan bracket from

blower assembly. The minimum of 0.010 inch measurement be-
b, With belt looped around driven install tween the bolt seating surface and the input
pulley,
369F5190 oil cooler fan bracket. shaft must be obtained to ensure proper clamp-
up. Warped shims or foreign material could pro-
NOTE
vide a false 0.010 inch minimum measurement
NAS1304 series bolts may be used in place of and improper clamp-up could result, which dur-
NAS6604 series bolts, ing normal operation, may damage the main
transmission input shaft.
1. InstallfourNAS6604H8 boltswith
AN960C416L washers through 369F5190 oil cooler i Coat threads of 369F5160 coupling bolt with
mounting bracket into 369D25626 fan bracket. anti-seize compound (6).
2. Before tightening bolts, displace cooler toward i, Lubricate input shaft splines and 369F5133
the transmission flange to eliminate slack in that coupling splines with grease (4).
direction, k- Install 369F5155 input coupling shim and cou-
3. Torqueboltsto irO-gOinch-pounds pling on transmission input shaft with coupling
bolt.
4. After bolts are torqued, seal around bolt heads
I, Adjust belt tension (Ref. Sec. 63-21-00, Cool-
with sealant (2, Table 2-1).
ing Blower Belt Tension Check and Adjustment).
c. Install pulley guard on main transmission in-
NOTE
put shaft.
Checkcoupling bolt for a minimum of 25 inch-
d, With belt looped around transmission input
pounds drag torque.
shaft, position mounting bracket on main transmis-
sion pad and loosely install two NAS6604H6 bolts m. Torque coupling bolt to 315 365 inch-
with AN960C416L washers from the bottom of pounds plus drag torque.
bracket and two NAS6604N7 bolts with
n, Connect drain tube to cooling blower scroll fit-
AN960C416L washers from top of bracket.
ting. Clamp tube to fitting with two turns oflock-
e. Before tightening bolts, insert one 369F5193 wire (11).
shim between bracket and transmission pad,
o. Roll exhaust duct rubber connectors onto scroll
f, Verify that blower scroll clears anti-torque outlets (transmission oil cooler duct and engine oil
drive shaft by a minimum of 0.190 inch. cooler duct) and secure with tie straps.
Original 2-21
or"
NAS6604HB 80LT
NAS6604HB BOLT
(NOTES1AND~
(NOTE 2)
369F5190-1
OIL COOLER FAN
369D25626
BRACKET
FAN BRACKET
NAS6604H7 BOLT
(NOTE 3)
969F5193-1SHIM
NAS6604H6 BOLT
\\\Y
369F5138-1
PULLEY GUARD
359F5133-1 COUPLING
369F5137-1
PULLEY DRIVER
369F5160-1 BOLT
(NOTE 4)
369F5155-1
INPUT COUPLING SHIM O
NOTES:
1. TORQUEBOLTS TO 70-901NCH-POUNDS.
2. AFTER TORQUING, SEAL BOLT HEADS WITH SEALANT (3, TABLE 201, 91-00-00).
3. TORQUE BOLTS TO 65-75 INCH POUNDS AND SAFETY WITH LOCKWIRE (150).
4. TORQUE COUPLING BOLT TO 315-365 INCH POUNDS PLUS DRAG TORQUE (DRAG TORQUE
TO BE NOT LESS THAN 25 INCH-POUNDS).
CSP102-012
Figure 2-11. Oil Cooler Blower Installation
2-22
Original
CSP- 102 Opt Eqpt Manual Section 2
2-27. 369F5450 Overrunning Clutch c- Slide overrunning clutch into engine and se-
Installation cure with six nuts and washers; torque nuts to 15
(Ref. Figure 2-12) The following procedure is for 20 Inch-pounds plus drag torque.
installation of the
larger 369F5450 overrunning d. Remove power output shaft cover plate from
clutch assembly. This procedure must be accom- back of engine (Ref. Sec. 01-00-00, Aliison Engine
plished before engine is installed in the helicopter. Operation and Maintenance Manual).
e, Install O-rings on 369F5469 (030 engine) or
Expendable Materials 369F5468 (C20 series engines) bolt.

Refer to Table 2-1
NOTE
Nomenclature Item Fill all voids and gaps between the outside of bolt
and inside of engine shaft with grease.
Grease 4
f. Lubricate bolt splines and inside of engine out-
put shaft with grease (4) and insert through engine
Remove nuts and washers securing 369A5350 into overrunning clutch assembly.
a.
series overrunning clutch assembly to engine power

gZ Insert a 3/8" hex wrench (approximately 10
and accessory gearbox; remove clutch assembly inches long) thru holding tool and into the bolt.
with firewall seal and coupling installed. to 250 300
Torque bolt inch-pounds plus drag
torque.
NOTE
h, Using existing hardware, reinstall power out-
The 369F5450 overrunning clutch comes serv- PUt Shaft cover plate on back of engine (Ref. Sec.
iced with 110 cc of oil and with the output drive 01-00-00, Allison Engine Operation and Mainte-
nance Manual).
coupling already installed,
L Position 369F5467 firewall seal assembly on
h. Coat external splines of overrunning clutch clutch with seam orientated to the six oclock posi-
and internal splines of engine power and accessory tion. Secure with three MS51957-42 screws and
gearbox with grease (4, Table 2-1). NAS620A8L washers.
Original 2-23
i92j
~P
369F5160 j
COUPLING BOLT 369F5133
COUPLING 369F5467-1 SEAL ASSEMBLY c~"
3X MS51957-42 SCREW
3X NAS620ABL WASHER
369F5450-501
CLUTCH ASSEMBLY
369F5468-1 BOLT (C20 SERIES ENGINEJ

369F5469-1 BOLT (C30 ENGINE)
M83248/1-019 PACKING
M83248/2-026 PACKING
NOTE
NOTE: LUBRICATE SPLINES BEFORE ASSEMBLY WITH GREASE 121, TABLE 201, 91-00-00).
PACK ALLVOIDS AND GAPS BEnnIEEN THE OUTSIDE OF BOLT AND INSIDE OF ENGINE
POWER OUTPUT SHAFT.
CSP102-013
Figure 2-12. 369F5450 Overrunning Clutch Installation
2-24
Original
2-28. Aircraft Reassembly NOTE

The following procedure is arranged in logical or- If installing the 369F5510 drive shaft, use three
der for reassembly of the helicopter after modif~ca-
3693321010-3 eyebolts and seven ~85798-4-26
tion; install the following: boltsin place of standard hardware (Ref.
Figure 2-13).
NOTE
d. Main rotor drive shaft (Ref. Sec. 63-10-10).
After tunnel-routed control tubes, swashplate
and mixer assembly, and main rotor hub are e- Anti-torque drive shaft access screen under
installed, run all controls through full range of intake fairings (Ref. Sec. 52-50-00).
travel and inspect for clearance with reworked fL Anti-torque flight controls on upper deck (Ref.
areas. Sec. 67-20-10 or 67-20-30).
~z Tunnel-routed control tubes (Ref. Sec. g, Intake fairings (Ref. Sec. 53-30-00 or
67-10-00). 53-30-30).
h, Engine and attaching hardware (Ref. Sec.

EL Mainrotorswashplate andmixerassembly 71-00-00 or 71-00-30).
(Ref. Sec. 62-30-00).
i Anti-ice cable assembly (if equipped with a
c. Main rotor hub (Ref. Sec. 62-20-00). 250-C20B engine) (Ref. Sec. 75-10-00).
369F551 0-1
MAIN ROTOR DRIVESHAFT
~L1
O
H55798-4 BOLT
(NOTE 2) NOTE 1
r~ 369D21010-3EYEBOLT
(NOTE 2)
O
1. HOLESTOBEIN UNEWITH HEUCOPTERHOISTSUNG.
2. TORQUE NUTS TO 120 140 INCH-POUNDS PLUS DRAG TORQUE. CSP102-014
Figure 2-13. 369F5510 Main Rotor Drive Shaft Installation
Original 2-25
i, Install 369A5000-40101 alignment tool be- a, AZlinteriortrim andinsulationincargo

tween engine and transmission ~Ref. Figure 2-14) compartment.
and check for maximum total offset of 0.050 inch
and total maximum wobble of 0.100 inch. If not
t. For 500N Model helicopters only:
within these limits, perform engine alignment (Ref
CSP-SRM-6).
1. Locate and mark MS-5100-134 panel for
k, Check overrunning clutch assembly oil level.
grommet hole (Ref. Figure 2-15).
CAUTION Cut 0.812 hole in

2. panel.
When installing the main transmission drive
shaft, use NAS6604-5 bolts. 3. InstallMS35489-14 grommet.
NOTE
u. Main rotor blades (Ref. Sec. 62-10-00).
NAS1304 bolts can be used in place of NAS6604
bolts.
i. Main transmission drive shaft (Ref. Sec.

TRANSMISSION SHAFT
63-10-00). CENTERLINE
m. Tailboom assembly (Ref. Sec. 53-40-00 or
53-40-30).
n. Horizontal and vertical stabilizers (Ref. Sec.
53-50-10 or 53-50-30). NOTE1
o. Tail rotor control rod

(Ref. Sec. 67-20-10).
assembly (369D/E/FF) ~uT NOTE 2
E Tail rotor gearbox and drive shaft (369D/E/FF) 0.100 MAX WOBBLE_IL
(Ref. Sec. 63-15-10). (RUNOUT)
3h9A5000-U)101
Tail rotor assembly (369D/EiFF) (Ref. Sec.
:LI CENTERLINE
64-20-00). INSPECTION TOOL
369A5000-40101
a, Sta. 124.00 bulkhead panels (Ref. Sec. (FASTEN TO
25-30-00). TRANSMISSION
COUPUNG)
NOTE
For replacement interior panels, contact:

Custom Aircraft Interiors o.loo MAX WOBBLE
3701Industry Ave. (AVNOUT)- ~_

Lakewood, CA 90712
The following is a list of panels that must be re-
placed with new panels when installing the
369F5100 transmission (Ref. Section i). OVERRUNNINGCLUTCH
CENTERUNE
1391ES:
Panels to Remove Panels to Install
i. WHEN INSTALLING DRNESHAFT, PEELSHIMTO
3693326542 H5-5100-134 OBTAIN +0.0101-0.020 AXIAL FIT.
Baffle Assy. Baffle Assy. 2. 0.050 MAXAVERAGE OF~SETATTHECOUPUNG
FLANGE WITH THE LARGEST MISMATCH (OFFSE~
3691126543-11 H5-5100-121 WHEN ROTATING TOOL ONE FULL TURN (360") 2 PL CSP102-015
Seal Assy. L/H Seal Assy. L/H
369D26543-21 H5-5100-122
Seal Assy. R/H Seal Assy. RM
369D22070 Blower H5-5100-103 Figure 2-14. Main Transmission Drive Shaft

Access Door Assy. Driveline Cover Runout Check
2-26 Revision 1
LOCATE THE 6.812 HOLE APPROXIMATELY

AS SHOWN. ME BAFFLE AND GROMMET MAY
BE SPUT TO FACILITATE INSTALLATION AND
REMOVAL OF THE WIRE HARNESS AND BAFFLE ASSY.
(FOR 500N MODEL AIRCRAFT ONLY.)
959026541-33
j 0.00
MS35489-14GROMMET~
(FOR 500N
AIRCRAFT ONLY) H
11 0.80 0.10
EXISTING GROMMET
FOR DRAIN TUBE
MS-5100-134
(503 500N MODEL
AIRCRAFT ONLY) I I SPUT LINE
(FOR 500N MODEL AIIRCRAFT ONLY)
2.00~ 0.10
VIEW LOOKING AFT

NORMAL TO REWORKED BAFFLE ASSY CSP102-018
Figure 2-15. MS-5100-134 Baffle Assembly Modification
2-29. Expendable Materials tute materials unless material is of equal quality

Materials in Table 2-1 approved
are for use on all and grade. See notes at end of Table 2-1.
Models of MDHS helicopters. Do not use substi-
Table 2-1. Expendable Materials
Commercial Product (2)
Item Specification
No. Material No. (1) Name/No Manufacturer
(See footnotes at end of table)
1 Solvent, dry-cleaning P-D-680 (3)
2 Sealing compound MIL-S-8802 890 Coast Proseal

Compton CA
MIL-S-8516 3C-3007 Churchill Chemical Corp.

Class II Los Angeles, CA
PR1422 Product Research

A1/2 Type I 2919 Empire Avenue
Burbank, CA 91504
Revision 1 2-27
Table 2-1. Expendable Materials

Commercial Product (2)
Item Specif~cation
No. Material No. (1) Name/No Manufacturer
RTV 730 Dow Coming

Type I, Class Midland, MI
3 Primer MIL-P-8585 (3)
4 Grease MIL-G-81322 Mobil Grease 28 Mobil Oil Company
Aero Shell 22 Shell Oil Company
5 Tape, Pressure sensitive PPP-T-66 Scotch Cal 3M Co.

(width and thickness as ~pe I, Class A #471 VEF St. Paul, MN 55144
noted)
6 Antiseize compound, high MIL-A-907 Silicone Dow Coming Corp.

temperature MIL-L-25861 DC-550R Midland, MI 48686-0994
7 Adhesive, bonding, vulca- MIL-A-1154 EC1300L 3M Co.
nized (synthetic rubber to St. Paul, MN 55144
steel)
8 Adhesive (epoxy) HMS16-1068 EA9330.3 HysolDivision

Class 1 Dexter Corporation
Pittsburg, CA
9 Cement Grip Taler Industries

City of Industry, CA
10 Epoxy primer 1-1G-69 Advance Coating and
Catalyst reducer 1-1H-75 Chemicals
11 Lockwire, CRES (3)

(0.032 inch-diameter)
12 Threadsealant P412 Permacel
13 Epoxy cement Hughes HP16-1 Type II Dow Coming Corp

EC 1300L Midland, MI 48686-0994
14 Acrylic, lacquer HMS 15-1100 (3) Advance Coating and
(color #s as noted 20371 Chemicals
parchment, 34151- green;
FED-STD-595)
NOTES:
(1) Numbers are Specifications and Standards. Prefix symbols are defined as follows: AMS Ameri-
U.S.A.
can MaterialsStandards; MS Military Standards; MIL Military Specification; Single, Double or tri-
ple alpha prefix of same letter Federal Specification; AN Air Force Navy Aeronautical Standard;
NAS NationalAerospace Standard.
(3) Use best comparable grade material when conformity of available materials of same type with listed
Specification No. cannot be determined.
2-28 Revision 1
The Boeing Company CSP-103
OPTIONAL EQUIPMENT ~ANUAL Litter Kit Installation
MDHS MODEL HELICOPTERS

and
Initial Installation, Maintenance and Inspection
Instructions
Litter Kit Installation, PN 600N90710
Model 600N Helicopters
McDonnell DozlBlas Helicogter Systems

5000 East McDotcell Road
Mesa, Arizona 86215-9797
Issued: 6 July 1998

NI FG I
IN~RO
The Boeing Company CSP-1OS
OPTIONAL EQUIPMENT MANUAL Litter Kit Installation
INSERT LATEST CHANGE PAGES, DESTROY SUPERSEDED PAGES

The asterisk indicates pages Revised or Added by the Current Change.
Date of original and revised pages are:
Original 6 July 1998
Page Revision Page Revision
CoverTTitle Original CONTENTS

CR-1A NIA i and ii Original
CR-2B N/A
CSP-103
TR 201 thru 208 Original
1/(2 blank) Original 901 thru 913/(914 blank) Original
LOEP 1001 thru 1013/(1014 blank) Original
A~B blank) Original
Page A/(B blank)

LOEP original
RECORD OF REVISIONS
CSP-003
MFG REV
7/6/98 5/2/05 ATPIMB

Library Addition
CSP-103

MCDONNELL DOUGLAS
HELICOPTER SYSTEMS
MANUAL TITLE: CSP-1OS. LITTER KIT INSTALLATION
REV. DATE DATE REV. DATE DATE

NO. INSERTED BY REMOVED BY NO. INSERTED BY REMOVED BY
Page 1/(2 blank)

TR Olig~nal
TABLE OF CONTENTS
Para/Figure/Table Title Page
CSP-1OS Litter Kit Installation, PN 600N90710 (600N) A
Maintenance Practices 201
1. Purpose and Contents of this Manual 201
2. Applicability 201
3. Component Mandatory Replacement 201
4. Organization of Contents 201
5. Related Publications 201
6. Literature Changes and Revisions 201
Figure 201. Litter Kit Installation 202
7. Litter Assembly Replacement 203
A. Litter,Assembly Removal 203
B. Litter Assembly Installation 203
Figure 202. Forward and Aft Litter Attachments 204
8. Aft Litter Support Assembly Replacement 205
A. Aft Litter Support Assembly Removal 205
B. Aft Litter Support Assembly Installation 205
9. Mid Litter Support Assembly Replacement 205
A. Mid Litter Support Assembly Removal 205
B. Mid Litter Support Assembly Installation 205
Figure 203. Litter Support Installation (Sheet 1 of2) 206
10. LitterKit Assembly Inspection 208
Initial Installation 901
1. 600N90710 Litter Kit Initial Installation 901
A. Preparation for Installation 901
B. HelicopterEquipment Removal 901
C. Seat StructureModficcatoo 902
Figure 901. Seat Structure Modification 902
D. SeatAccess Cover Installation 903
Figure 902. Seat Access Cover Installation 903
E. Canted Sta. 78.50 Bulkhead Seat Back Removal 904
Figure 903. Canted Sta. 78.50 Bulkhead Seat Back Removal 904
F. Canted Sta. 78.50 Bulkhead Seat Back Gusset Installation 905
G. ShoulderBeam Installation 905
Figure 904. Canted Sta. 78.50 Bulkhead Seat Back Gusset Installation 905
Figure 905. Shoulder Beam Installation (Sheet 1 of 3) 907
H. Litter Clamp Restraint Installation 910
Figure 906. Litter Clamp Restraint Installation 910
Pagei
Contents Original
CSP-103 The Boeing Company
Litter Kit Installation OPTIONAL EQUIPMENT MANUAL
TABLE OF CONTENTS (Cont.)

Para/Figure~able Title Page
I. Canted Sta. 78.50 Bulkhead LowerWeb Installation 911
Figure 907. Canted Sta. 78.50 Bulkhead Lower Web and Forward Litter
Support Installation 912
J. Aft Seat Belt Fitting Rivet Replacement 913
Figure 908. Seat Belt FittingRivet Replacement 913
Illustrated Parts List 1001

i. Scope and Contents 1001
2. Group Assembly Parts List 1001
3. Illustrations 1001
Figure 1. Litter Kit Installation (Sheet 1 of4) 1002
Figurea. LitterAssembly LitterKit 1009
Figure 3. Support Assemblies Mid Support Assy/Aft Support Assy 1012
Page ii
Original Contents
CSP-1 03
Litter Kit Installation,
PN 6001\190710
(600N)
The
Boeing Company CSP-103
OPTIONAL EQUIPMENT MANUAZI Litter Kit Installation
LITTER KIT INSTALLATION, PN 6001\190710
MAINTENANCE PRACTICES
1. Purpose and Contents of this Manual At the listed inspection interval, the compo-
nents or assemblies must be inspected in
This manual supplements information accordance with the Handbook of Maintenance
contained in the Handbook of Maintenance Instructions (HMI).
Instructions (CSP-HMI-8) and the Illustrated
Parts Catalog (CSP-IPC-U. This manual
4. Organization of Contents
contains an Illustrated Parts List (IPL) for
procuring replacement parts and instructions The contents of this manual are grouped into
for initial installation of the 600N90710 Litter
sections as outlined in the Table of Contents.
Kit Installation.
Each section is organized to provide compre-
hensive coverage of the systems, major
2. Applicability
equipment groupings and major components
This manual is only to be used for the litter kit that are similar or associated. Procedures for
installation for the 600N Model helicopter. For each of these are presented in sequence as
flight information and characteristics, refer to defined in Introduction (Ref CSP-HMI-8).
applicable Rotorcraft Flight Manual.
5. Related Publications
3. Component Mandatory Replacement
Reference is made throughout this CSP to
The Airworthiness Limitation Replacement
CSP-HMI-8 and CSP-SRM-6. These manu-
Schedule (Ref. Sec. 04-00-00, CSP-HMI-8)
als should be used as noted throughout the
specifies the mandatory replacement time, conversion. The Illustrated Parts Catalog
structural inspection interval and related
(CSP-IPC-4) should be used for ordering any
structural inspection procedures approved per
the certificate basis of the Type Certificate
replacement parts required.
Data Sheet No. HSWE and CAR 6 (6.250,
6. LiteratureChanges and Revisions
6.251).
At the listed finite-life hours, components or Changes and revisions to contents of this
assemblies must be removed from the helicop- manual are made as def~ned in the Introduc-
ter and permanently retired from service. tion of CSP-HMI-8.
Page 201
CSP-103 Original
PASSENGER
SEAT FRAME
AFT SUPPORT
SEAT BACK PANELRMOVB GO-PILOT

LITTER
MID SUPPORT
SEATTRACK
STA.78.50 BULKHEAD
FORWARD SUPPORT
PILOT SEAT STRUCTURE
CSP103-014
Figure 201. Litter Kit Installation
Page 202
original CSP-103
The Booing Company CSP-103
7. Litter Assembly Replacement B. Litter Assembly Installation
(1). Remove co-pilot seat back panel.

(Ref. Figure 202)
(2). Unfold and insert one end of litter
A. Litter Assembly Removal though co-pilots seat structure.
(3). Slide litter forward until litter rear lug

(1). Remove pip-pin from aft litter support
lines up with aft support clamp.
and open latch.
(4). Insert litter rear lug into aft support
(2). Lift litter until litter lug clears aft
rear clamp and close clamp.
support and slide litter to the rear until
forward end clears litter clamp re- (5). Insert pip-pin into aft support clamp.
straints.
(6). Secure litter to co-pilot seat structure
by installing forward litter restraint
(3). Rotate litter and remove from aircraft. clamps.
Page 203
CSP-103 Original
CSP-103 Boeing Company
PASSENGER SEAT
SUPPORT
PIP-PIN
n J
~D ~D ~o
fj
ATTACH LUG i II
ijj
m~ar oo
AFT SUPPORT ASSEMBLY

j/
STRAP ASSEMBLY VIMT LOOKING DOWN
L._.._.._._.._.,.U
i i i i i i
to CAM LOCK r--------
CLAMP.
PIP-PIN i
O O
ROTATED
ATTACH LUG
O nF1 umR nrmcnMENT
STA 78.50 BULKHEAD
UTTER
FORWARD UTTtiR CLAMP RESTRAINTS

(RH SHOWN, UH OPPOSITE)
ROTATED
I
__
-~---_
PILOT SEAT STRUCTURE
CSP103-015
Figure 202. Fonnrard and Aft Litter Attachments
Page 204
Original CSP- 103

8. Aft Litter Support Assembly Replacement 9. MidLitterSupportAssembly

Replacement
(Ref. Figure 203) (Ref. Figure 203)
A. Aft Litter Support Assembly Removal A. Mid Litter Support Assembly Removal
(1). Remove litter assembly.
(1). Removelitter.
(2). Remove pip-pins at base of mid support
(2). Unlatch strap assemblies from passen-
assembly and remove support from
aircraft.
ger seat supports.
B. Mid Litter Support Assembly Installation
(3). Remove pip-pins from aft support legs.
NOTE: Ensure the diagonal brace is installed
in mid support.
(4). Slide support legs from seat frame and
remove support assembly. (1). With standard mid-cabin bench seat
installed:
B. Aft Litter Support Assembly Installation
(a). Align support legs with holes in seat
track.
(1). Slide aft support legs into holes in seat
frame and slide down until collars (b). Attach support legs to seat track
bottom on frame. with pip-pins.
(2). With optional mid-cabin business seats
(2). Install pip-pins in support rods. installed.
(a). Align support legs with brackets on

(3). Latch strap assemblies onto pins in
I-beams.
passenger seat supports.
(b). Attach support legs to brackets with
(4). Install litter assembly. pip-pins.
Page 205
CSP-103 Original
\I
UTTER
PIP-PIN
O AFTSUPPORT
PASSENGER SUPPORT
Y PASSENGER SEAT FRAME
PIP-PIN
1L M_ n __11_
VIEW LOOKING INBOARD
CSP103-016-1
Figure 203. Litter Support Installation (Sheet 1 of 2)
Page 206
Ori~inal CSP-1OS
The Booing Company CSP-1OS
PIP-PIN
SUPPORT LEGS
DIAGONAL BRACE
WITH STANDARD BENCH SEAT, SUPPORT

LEGS ATTACH TO INSIDE OF SEAT TRACK.
(LH SHOWN, RH SIMILAR)
WITH OPTIONAL BUSINESS SEATS, SUPPORT

O MIDSUPPORT LEGS ATTACH TO BRACKETS INSTALLED ON
I-BEAMS. (RH SHOWN, LH SIMILAR) plp_plly
CSP103-016-2
Figure 203. Litter Support Installation (Sheet 2 of 2)
Page 207
CSP-103 original
CSP-103 The
Boeing Company
10. Litter Kit Assembly Inspection (5). Inspect all welds for condition, reweld
as necessary.
Consumable Materials
(6). Inspect litter restraint straps for
(Ref.
Section 91-00-00)
fraying and security, no fraying al-
Item Nomenclature
lowed.
CM304 Enamel, epoxy
CM206 Chemical coating (7). Inspect strap assembly for fraying and
condition of latch, no fraying allowed.
CM318 Primer
(8). Inspect passenger seat supports for

(1). Inspect all hardware for security, elongated pin holes, 0.190-0.196 inch
retorque loose hardware. (4.826-4.978 mm).
(2). Inspect pip-pins for freedom of plunger (9). Inspect aft litter support assembly for
movement, security of locking ball and loose screws, excess wear in support
locking ability, clean or replace as plate cutout and latch for security.
necessary.
(10). Inspect mid litter support assembly for
(3). Inspect all pip-pin holes for elongation, security and condition.
All pip-pin holes to 0.191-0.196 inch
(4.851-4.978 mm). (11). Inspect for chippedmissing paint,
or
treat surfaces with chemical
coating
(4). Inspect litter kit tubing for cracks or (CM206), primer (CM318) and paint
damage, no cracks allowed. (CM304).
Page 208
Original CSP- 103

600N9071 O LITTER KIT INSTALLATION
INITIAL INSTALLATION
1. 600N90710 Litter Kit Initial Installation (2). Protect all components from damage
and foreign matter.
Consumable Materials (3). Ensure all electrical switches

are in
(Ref. Section 91-00-00) OFF position and BATT-OFF-EXT

Item Nomenclature PWR is OFE
CM304 Enamel, epoxy B. Helicopter Equipment Removal

CM206 Chemical coating
(1). Remove crew and passenger seats.
CM318 Primer
(2). Remove crew compartment trim panels
as required.
A. Preparation for Installation
(3). Remove right-hand heater duct from
Sta. 78.50 bulkhead.
(1). Identify all components of litter kit
including attaching hardware and (4). Remove center seat inertia reel and
components removed to gain access to bracket, reinstall rivets though tunnel
work areas. beam only.
Page 901
CSP-103 Original
C. Seat Structure Modification (5). Measure 10.80 inches (27.432 cm) to

the right of previous line and mark fore
(Ref. Figure 901) and aft across seat structure.
(6). Mark the radius of the four corners as

(1). Remove access panel between pilot seat
per Figure 901.
structures.
When cutting seat structure,
CAUTION
(2). Measure 2.03 inches (5.1562 cm) aft GrrmYYmYJ the stiffener under seat
ensure
from front of R~H seat structure and structure is not disturbed.

mark across seat structure.
(7). Being careful not to cut the stiffener
under the seat pan, cut seat pan
(3). Measure 11.70 inches (29.718 cm) aft leaving enough material for clean-up.
from previous line and mark across seat
structure. (8). Deburr sharp edges.
(9). Treat with chemical film (CM206).

(4). Measure 1.95 inches (4.953 cm) from
L/H edge of seat structure and mark (10). Touch up with primer (CM318) and
fore and aft across seat structure, paint (CM304).
II.70 INCH _1 2.03 INCH

(29.718 CM) (5.1562 CM)
I i 1.95~1NCH
ii (4.953 CM)
R 1.75
54.(HCCNI)
NI
CUTOUT THRU SEAT

STRUCTURE
10.801NCH
(27.432 CM)
FWD
STIFFENEASEATSTRUCTVRE
R4.351NCH(1 .049 CM) el

WR1.1OINCH
(2.794 CM)
e
t-------------------
i_____ __
__I __ __ __ __ __ __ __ __
___I
CSP103-010
Figure 901. Seat Structure Modification
Page 902
Original CSP-103
D. Seat Access Cover Installation (3). Install screws with washers in holes to
secure cover to seat structure.
(Ref. Figure 902) (4). Using existing pilot holes in access
cover, drill 17 holes in seat structure.

(1). Position 600N90714-25 seat access
(5). Enlarge previously drilled holes to
cover over access hole flush with left
13/64 inch (5.159375 mm).
side and 0.53 inch (13.462 mm) aft of
front of seat structure. (6). Remove panel and deburr holes.

(2). Using a hole finder, drill five 13/64 inch
(5.159375 mm) screw holes on left- (8). Touch up with primer (CM318) and
hand side of cover. paint (CM304).
5X NAS7703-2 SCREW
5X NAS1149F0316P WASHER
PICK UP MISTING NUTPLATE LOCATIONS
SEIIIICCESSCOVER
17X NASn03-2 SCREW

17X NAS1149F0316P WASHER
17X MS21076L3N NUTPLATE
34X MS20426AD3-4 RIVET
LOCATE FROM PILOT HOLES
INCOVER
I--- -_
CSP103-OH
Figure 902. Seat Access Cover Installation
Page 903
CSP-103 Original
E. Canted Sta. 78.50 Bulkhead Seat Back (e). Mark aline vertically, on the inside
Removal edge of the 369D22508-38 stiffener,
from previous line down to the top
(Ref. Figure 903)
edge of lower seat structure stiffener.
Irrmmrrmp
CAUTION
When drilling rivets in tunnel
L___. ,1 drill stop to prevent (f). Mark a line from the tunnel beam to
_
area, use a
the vertical line on the shoulder
damage to control tubes, fuel vent system
and wires inside the tunnel. beam along the lower side of the
stiffener.
NOTE: When marking panel and stiffeners, en-
sure proper rivet edge distance. (g). Mark a line vertically along the
tunnel beam from the shoulder beam
(1). Mark bulkhead as follows:
stiffener down to the 369A2544-4
(a). Count in five rivets from the fitting.
369D22508-38 stiffener and mark a
vertical line on the shoulder beam (h). Mark around 369A2544-4 fitting
lower stiffener. down to top edge of lower seat
structure fitting.
(b). Count in four rivets from the tunnel
beam and mark a vertical line the (i). Mark
on across top edge of lower seat
shoulder beam lower stiffener. structure fitting.
(C). Mark a line between previous lines
along shoulder beam above rivet line. (i). Radius all corners to 0.125 inch
(3.175 mm) except wear denoted in
(d). Mark a line from the inside edge of Figure 903.
the 3691122508-38 stiffener to the
vertical line on the shoulder beam (2). Cut bulkhead as marked leaving
along the lower side of the stiffener. enough material for clean-up.
I
CUTOUT EDGE
36~m1Y1838
fl
STIFFENER
R 2.0 IN. (5.08 CM)
~-6_rll
CSP103-012
Figure 903. Canted Sta. 78.50 Bulkhead Seat Back Removal
Page 904
Original CSP-103
(3). Deburr sharp edges. (5). Locate 600N90714-35 shim and

600N90714-33 gusset on
(4). Treat with chemical film (CM206). 369D22508-38 stiffener at shoulder
beam and back-drill rivet holes.
(5). Touch up with primer (CM318) and
paint (CM304). (6). Locate camloc receptacle on gusset,
bottom rivet hole clocked approximately
(6). Remove nutplates at seat base stiffener 35" outboard, and drill using a #31 drill
and reinstall MS20426AD3 rivets in bit.
empty holes. Install HS5603-6-3 pins,
NAS1149FN816P washers and (7). Treat rivet holes with chemical film
HS5583-6 collars in fastener holes. (CM206).
F Canted Sta. 78.50 Bulkhead Seat Back (8). Install shim, gusset and camloc
Gusset Installation receptacle.
(Ref. Figure 904) (9). Touch up with primer (CM318) and

paint (CM304).
NOTE: All rivets are to be installed wet with
G. Shoulder Beam Installation
primer (CMS1~).
(Ref. Figure 905)
(1). Remove rivets as per Figure 904.
(1). Position 600N90714-5 upper web on
(2). Locate 600N90714-35 shim and
top of shoulder beam and flush against
600N90714-31 gusset on tunnel beam aft side of tunnel and 369D22508-13
at shoulder beam and back-drill rivet
frame.
holes.
(2). Remove rivets from seat base that fall
(3). Locate camloc receptacle on gusset, under upper web.
bottom rivet hole clocked approximately
20" inboard, and drill using a #31 drill (3). Grind rivnuts marked A (view E) in
bit, shoulder beam flush, these holes will
remain open; treat with chemical film
(4). Install shim, gusset and camloc (CM206) and touch up with primer
receptacle. (CM318).
4X NAS1919C04S02W RIVET
10X NAS1919C04S02W RIVET
PICK UP MISTING
PICK UP MISTING
LOCATIONS AND CAMLOC HS4435-2 CAMLOC
LOCATIONS AND CAMLOC
RECEPTACLE PICK UP ONE
MISTING RIVET LOCATION
iw+
4X NAS1919C04S04W RIVET ~-!-T;K7Y7 f CU-XT1-I~
PICK UP WISTING
SHOUU)ER BEAM
LOCATIONS 350
200
600N90714-31 600N90714-33
INBOARD GUSSET OUTBOARD GUSSET
600#90714-35 SHIM
600N90714-35 SHIM I
369[)22508-38STIFFENER
Jt~.NNNasEnM /j
CSP103-013
Figure 904. Canted Sta. 78.50 Bulkhead Seat Back Gusset Installation
Page 905
CSP-103 Original
(4). Reinstall upper web in place. (17). Position 600N90714-11 beam gusset on
front of upper beam and tunnel.

(5). Drill and cleco upper web in place.
(18). Drill and cleco in place.
(6). Position 600N90713-3 and -4 brackets
with 600N90713-1 box together (view (19). Remove box/brackets from aircraft.
D).
(20). Measure 2.77 inches (7.0358 cm) from
-3 bracket and 1.50 inch (3.81 cm) from
NOTE: Ensure 600N90713-3 and -4 brackets
bottom of box and mark; this is the
are positioned properly and securely against
center for the inertia real.
600N90713-1 box before drilling rivet
holes.
(21). Position inertia real and match drill
four bolt holes.
(7). Drill and cleco brackets and box
together. (22). Locate MS21076L3 nutplates on aft
side of box.
(8). Position box/brackets against upper
web, 5.92 inches (15.0368 cm) from (23). Drill and cleco in place.
tunnel, with brackets mounted securely
on top of shoulder beam.
(24). Remove parts from aircraft and deburr
rivet holes.
When drilling rivets in tunnel
CAUTION-1
s----------
area, use a drill stop to prevent (25). Treat with chemical film (CM206).
damage to control tubes, fuel vent system
and wires inside the tunnel. (26). Touch up with primer (CM318) and
paint (CM304).
(9). Drill and cleco rivet holes common to
brackets/box and upper web. NOTE:
a All rivets are to be installed wet with
(10). Position 600N90714-3 upper beam
primer (CM318).
bottom on brackets and box with flange
flush against tunnel. Before riveting parts in place, ensure all
rivets are accessible.
(11). Position 600N90714-1 upper beam top
on upper web and upper beam bottom
(27). Install inertia real nutplates on
with flange flush against tunnel. box~rackets.

(28). Rivet brackets to box.
(12). Drill and cleco rivet hole common to
upper beam top and bottom.
(29). Rivet upper beam top and bottom
together using rivets holes that are not
common to other parts.
upper beam top and upper web.
(30). Rivet box/brackets to upper beam.
upper beam top/bottom and box/brack-
(31). Position upper beam with box/brackets,
ets.
clips, gussets and upper web in place.
(15). Position 600N90714-7 upper angle clip (32). Rivet upper beam with box/brackets,
on top of upper beam top, flush against
clips, gussets and upper web in place.
369D22508-13 frame.
(16). Position 600N90714-9 lower angle clip
against upper beam bottom, flush (34). Touch up with primer (CM318) and
against 369D22508-13 frame. paint (CM304).
Page 906
Original CSP-103
600N90714-7UPPER
NAS 1919C04S02W 600#90714-1 UPPER ANGLE CUP _
369022508-13
BEAM TOP FRAME
RIVET (23 PLCS)
NAS1 919C04S02W
TUNNEL BEAM 600#90714-5 RIVET (14 PLCS)
UPPER WEB NAS1919C04S01W
NAS1919C04S02W
RIVET
RIVET
+I/-: f f
+/t /r f C f
RIVET
h (NOTE 1)
I I+ I j
NAS1738B4-3
RIVET(1OPLCS)
+I
j
NAS1919C04S01W
RIVET (7 PLCS)
+I i+l!-----___-----_----___!
I +I
------________----__.:--I
I-- !r~t-------------
I ~__________________: I Ir------------
i-
-t i-
VIEW LOOKING FORWARD I:
NAS1919C04S04W
MS21076L3N NUT- RIVET (3 PLCS)
NASIS1 9C04S04W
PLATE (4 PLCS)
RIVET (21 PLCS)
600#90713-1
BOX
-I
BEAM GUSSEI
+I;H i i i i./+ i i +I+ ++F~lj
I NAS1738B4-3
RIVET (3 PLCS)
2.TI IN.
1.501N.
600N90713-4 (7.0358CM)
600#90713-3
BRACKET
BRACKET
TUNNEL BEAM
5.92 IN.
(15.0368 CM)
VIEW~LOOKING AFT
NOTES:
1. PICKUPEXISTING RIVETLOCATION.
2. GRIND RIVNUTS FLUSH WITH SHOULDER BEAM, HOLES MARKED A HOLES TO REMAIN OPEN AT
INSTALLATION OF LITTER STRUCTURE.
3. APPLY 1 X 2 IN. (2.54 X 5.08 CM) PIECES OF HOOK TAPE WITH PRESSURE SENSITIVE ADHESIVE
BACKING TO LOWER SIDE OF UPPER SHOULDER BEAM. CSP103-017-1
Figure 905. Shoulder Beam Installation (Sheet 1 of 3)
Page 907
CSP-103 Original
600N90714-7UPPER
ANGLE CUP (5.588 MM)
NAS173884-2 RIVET
NAS1S1SC04S02W
RIVET (5 PLCS)
~it 0.50 IN,
600N90714-1 UPPER
BEAM, TOP
600N90714-9 LOWER
ANGLE CUP
f f
NAS1919C04S02W
RIVET NAS1738B4-2 RIVET
(4 PLCS)
600N90714-1 UPPER
(MID O YIEW LOOKING LIUTBOCIRO BEAM, TOP
600N90714-3UPPER
BEAM, BOTTOM
600Ns0714-5_ 11 3+
UPPER WEB
600N90713-4 BRACKET
NAS1669-08L4 BUND
ii+ FASTENER (6 PLCS)
369D22508 600N90713-1BOX
SHOUU)ER BEAM
2.001N. I
(5.08 CM) O wcnW LO~KINO INB~IRD FWD
NASi919C04S03W
RIVET (5 PLCS)
0,12
(3.048 MM)
IN.j! 0.27 IN.
(6.858 MM)
NAS173885-3 RIVET
0.381N.
(9.652 MM) NAS1739B5-2
RIVET
J
0.84 IN.
Tf- .336MM)
NAS173985-2 RIVET
-tf+
600N90714-1 UPPER
BEAM TOP
NASi919C04S03W
600N90714-3UPPER RIVET (6 PLCS)
BEAM BOTTOM
FWD
CSP103-a17-2
Page 908
Original CSP-103
600N90714-9 LOWER
ANGLE CUP
NAS1669-0812 BUND
soaNson3-4 FASTENER (5 PLCSJ 600N90713-3
BRACKET BRACKET
NOTEB
NAS1919C04S02W. \Ij~S8 I f f f If
RIVET (6 PLCS)
I NAS1669-OBU BLIND
If fl;
I FASTENER (3 PLCS) TUNNEL BEAM
I I
If t f t f f +I
NAS1919C04S02W
NAS1669-0811 BLIND 600N90713-1 BOX
RIVET(21 PLCS)
FASTENER (3 PLCS)
IDI WI OMNYLOOKINGUP
NAS1669-OBB2 BUND
FASTENER (2 PLCS) NAS173884-2 RIVET
NAS173984-2 RIVET
NAS1919C04S02W (15 PLCSI (NOTE 1)
(6 PLCS) (NOTE 1)
RIVET (7 PLCS) NAS1669-08B2 BUND
NOTEP
FASTENER (2 PLCS)
-t- -I- -I -I- -I-
+Y+ II IAI-I--F- -I- -1- -iP1 lrl~Si f

-1-4
Al- -I- -I- -I- -I- -I- -~Al I)
NOTE 3 600#90713-3
BRACKET
NAS1 91 9C04S02W
600N90714-5
RIVET(IIPLCS)
600N90713-4 UPPERWEB
BRACKET
IFI~wi O UEWUX~INOOOWN
CSP103-017-3
Page 909
CSP-103 Original
H. Litter Clamp Restraint installation (4). Install lanyards.
(Ref. Figure 906)

(5). Locate camloc receptacles on gussets
NOTE: All rivets are to be installed wet with and drill rivet holes.
primer (CM318).
(1). Locate L/H and R/H litter restraints (6). Locate lanyards on gussets and drill
and gussets. rivet hole.
(2). Locate lanyards on litter restraints and

(7). Deburr rivet holes and treat with
drill rivet hole.
chemical film (CM206).
(3). Deburr rivet holes and treat with
chemical film (CM206). (8). Install camloc receptacles and lanyards.
UTTER RESTRAINT
LTTWRESTIWNT-
fl6UWomGUSSEI
CAMLOC
i
CAMLOC
CAMLOC
RECEPTACLE
1.2601N.
LANYARD,, ,- f
RIVET
(3.2004 MM)
(7.112 MM)0.2801N. LANYARD
0.1901N.
(4.826 MM)
SUPPORT GUSSET
0.190 IN.
(4.826 MM)
ROfATED
CSP103-009
Figure 906. Litter Clamp Restraint Installation
Page 910
Original CSP-1OS
i. Canted Sta. 78.50 Bulkhead Lower Web (8). Locate web stiffeners on lower web.
Installation
(9). Using pilot holes on stiffeners, drill web
(Ref. Figure 907) and cleco stiffeners in place.
NOTE: (10). Remove clecos, deburr rivet holes and
All rivets are to be installed wet with treat with chemical film (CM206).
primer (CM318). (11). Rivet stiffeners to web using rivets
Refer to Figure 1 for proper rivet sizes. holes that are not common to any other
To ease in installation of the lower web, parts.
the seat structure modification should be
(12). Reinstallweb on canted Sta. 78.50
completed first. bulkhead with clecos.
(1). Place 600N90714-27 lower web against
aft side of canted Sta. 78.50 bulkhead (13). Back-drill rivet holes and cleco web in
as shown and mark rivets and nut-
place.
plates to be removed. (14). Position forward litter support, drill
and cleco in place.
CAUTION
When drilling
rivets in tunnel
t~mmwulu area, use a drill stop to prevent
(15). Position web stiffeners on web, drill and
damage to control tubes, fuel vent system cleco in place.
and wires inside the tunnel.
(16). Position web doubler in place, drill and
(2). Remove marked rivets and nutplates. cleco in place.
(3). Cut 369D22508-27 doubler to clear
(17). Position inner, outer and middle
lower web.
support gussets in place, drill and cleco
(4). Treat with chemical film (CM206). in place.
NOTE: It will be necessary to reposition the (18). Using seat back as a template, position
wire harness running from the footwell to lower camloc receptacle on web doubler,
install the lower web, drill and cleco in place.
(5). Position lower web on bulkhead, with (19). Remove clecos, deburr rivet holes and
wire harness routed through cut-out, treat with chemical film (CM206).
(6). Mark lower web to clear rivets and (20). Reinstall web, camloc receptacle, litter
remove. support and gussets with clecos.
(7). Trim marked edges and treat with (21). Cut grommet and install around wire
chemical film (CM206). harness into web doubler.
Page 911
CSP-103 Original
CSP-103 The Booing Company
600N90714-24 600N90714-23
UTTER CLAMP UTTER CLAMP 600Ng071e33
600N90714-21 RESTRAINT OUTERSUPPORT
RESTRAINT
FORWARD UTTER GUSSET
SUPPORT
600#90714-31 1 CAMLOC
INNERSUPPORT 600#90714-17
369[)22508-27
GUSSEF MIDDLE SUPPORT
DOUBLER GUSSET NUTPLATE
(NOTE 1) (REMOVE)
3 r~t4
II II
-I- II -I- -1- 4- 4- -1- -I- -1- 4-

t
ti
600N90714-29 Ilf
f
WEBDOUBLER II
CAMLOC
NUTPLATE RECEPTACLE "fi I II
-e f II
0.64 IN. (REMOVE) (NOTE 3) 11 0.64 IN. II C-
HS5M18-185
GROMMET
(16.256MM)+ F6.256MM) I/
II
-t -t
[I -I-ilo
r +I ~I+ ii
6005190714-13 (!f
WEB STIFFENER
II+ I
s f
E II
it II
II+ I~+ I
II
II+ nf
1- 1_ __ I- I- 1- I -r I- iO
NOTEP
600N 90714-27
LOWER WEB NOTE2
II
CANTED STA. 78.50

BULKHEAD
NOTE:
1. CUTDOUBLER TO CLEARWEB.
2 TRIM CORNER, AS REQUIRED, TO CLEAR RIVET BY A
MINIMUM EDGE DISTANCE OF 20.
3. CAMLOC RECEPTACLETO BEADJUSTEDAND ROTATED
TO ACCOMMODATE CAMLOC STUDS ON SEAT BACK.
CSP103-008
Figure 907. Canted Sta. 78.50 Bulkhead Lower Web and Forward Litter Support Installation
Page 912
Original CSP-103
J. Aft Seat Belt Fitting Rivet Replacement
(Ref. Figure
908)41-I-1
(1). Remove upper five rivets between
seat belt fitting channels. both1 REMOVE MISTING FIVE RIVETS
ON BOTH SEAT BELT FITTINGS AND
REPLACE WITH NAS1738CW4-2 OR
(2). Countersink rivet holes. NAS1738M4-2 BLIND RIVETS
-I-
(3). Treat with chemical film (CM206). I-
(4). Touch up with primer

(CM318).-I--I-
NOTE: All rivets
primer (CM318).
are to be installed wet with
b 1 -I-
(5). Install NAS1738CW4-2 or ~__

I
NAS1738M4-2 blind rivets. CSP103-018
(6). Touch up with primer (CM318) and Figure 908. Seat BeltFitting Rivet
paint (CM304). Replacement
Page 913/(914 blank)

CSP-103 Original
LITTER KIT INSTALLATION, PN 800N90710

1. Scope and Contents 2. Group Assembly Parts List
The following information is provided to aid

This illustrated parts list provides, by means the user, by means of text and detailed
of text (parts list) and companion illustrations, illustrations, for parts procurement only and
a complete parts definition of the 600N90710 shall not be used for any other purpose. This
Litter Kit Installation and applies to the Model IPC should not be used for maintenance
600N helicopter manufactured by McDonnell Pwr~oses.
Douglas Helicopter Systems, Mesa,AZ.
3. Illustrations
NOTE: The illustrated parts list is organized Illustrations are provided for each group
and presented in the the
same manner as assembly parts list. Each illustration is
369D/E/FF 500/600N Illustrated Parts exploded to the extent necessary to show parts
Catalog (CSP-IPC-4). For information on relationship for the complete Litter Kit
use, refer to CSP-IPC-4. Installation.
Page 1001
CSP-103 original
33 32
36
Y iI
Il II
jBjl/
jiiI jj
j
I 1
2 X ii
i~-\
46
iPi
II6
-I-
-1-
II
50
36
70
79Bo
66 (2)
\u
68
30
O 0110
000
32 63
O
i
O
32
35
1
600N25401(REF)
81
65 82
66
33 \171
(-501 INSTALLATION)
1~i.
2 172
73 31
(-503 INSTALLATION)
60103-005-1
Figure 1. Litter Kit Installation (Sheet 1 of 4)
Page 1002
Original CSP-103
The Peeing Company CSP-103
12
Tr ~8 38 L
10
38
41
i-; i i i +/t t i i i i i i. i i i
i -r +I
i
I
43
I, I
i:;::::::i i:
ii I 37
(4 PLS) 38, i+~ll---------------------i f
~t L__ iv;
,______________ :-~t;l--
II ir
I__________________,
(4 PLS) 40~ L\_C_-----------
c 27
f 28 38
29 (8 PLS)
BPLS)
24
25
I\-I-
26
23
Y
-I- 1: 18
63
26
SAME OPPOSITE SIDE
52
19
59
63 127 44 (3 PLS)I~ y I /1 60
28 /1)/1 Y 164
57 15 A 29 (2 PLS)
58 62
64 _L~%II 1 .44
49 1 1 ,41 14
21
I /55
Is\
57 1 T;I~
(3 PLS) 56 58
-I- +1 64 57
17 3
1
-I- i 58
22 64
i
13
13
~I j
9
C
ii
-1- 3
61
;95p8~ ii
(10PLS) 51
-1-
i+ f j (10 PLS)
45
-I-
i+ T
(13 PLS) 42
/f-l-~il--+ i
-1- 3 -1- i
J_
SI-I- -I-r-I-I-~ O
21
f I
42
VIEW LOOKING FORWARD 60103-005-2
Page 1003
CSP-103 Original
,7~ 45
38
J
(SPLS~ +t 1/+~ B i-.+
47
42
11 39
6
j/ (5 PLS)
7
55
a,/+ 39
7
9 (6 PLS) 47 f
PLS)
42
38 (4 PLS)
54
Itt
f +II
I+ Ij
38 I
1
\---------------s------------,
If l-ff+ i
38 53
38
38 4 53
40
38
80 4
PLS)
12
+i
i=
:a
43
-~F---J IA
a I 1 5
48
54
54
-I-
-t -i- 9 -1- i--1-"1I1,Yi~+
-i- -I- ~-e
A_t_ _I_ II~ t~. 4 -1- _~-A
38
6
O 38
9 42 (14 PLS) 5
60103-005-3
Page 1004
original CSP-103
17,
,i
i/i
is
~1
q~ 152(s
76 1/ 81 79
(2) 77 82 80
(17PLS)
\9 6p103-005-4
Page 1005
CSP-103 original
Litter Kit Installation OPTIONAIL EQUIPMENT MANUAL
Qty. Used
L Pig. Item
per on Model! Serial No.
L No. No. Part Number Description Assy. Code From To
1 600Ng0710-501 Litter Kit Installation
a For A 600N 000001SUBS
With Mid Seat
1 600N9071~503 Litter Kit Installation Instl
a For A/C With REF B 600N 000001-SUBS
Business Seats
1 1 600N90711501 Mid Support Assy, Litter Kit
a a 1
See Pig 3 For BKDN
1 2 600N90712-501 a a
Support Assy, Aft End 1
See Fig 3 For BKDN
1 3 Not Use
1 4 6001\19071 3-1 Box 1
1 5 600N9071 ~-3 Bracket I 1
1 6 600N9071 3-4 Bracket I 1
1 7 600N90714-1 a a
Upper Beam, Top 1
1 8 600N90714-3 a a
Upper Beam, Bottom 1
1 9 600N90714-5 a
Upper Web 1
1 10 6001\190714-7 a a Upper Angle Clip 1
1 11 600N90714-9 Lower
a
Angle Clip 1
1 12 600N90714-11 Beam Gusset
a a
.........,._.,..
1
1 13 600N90714-13 a a Web Stiffener 1 2
1 14 600N90714-15 Outboard
a
Support, Gusset 1
1 15 600N90714-17 Middle
a a
Support, Gusset 1
1 16 6001\190714-19 Inboard
a
Support, Gusset 1
1 17 600N90714-21 Forward Litter
a a
Support 1
1 18 600N90714-23 Litter
a
Clamp Restraint 1
1 19 600N90714-24 Litter
a a
Clamp Restraint 1
1 20 600N90714-25 Seat Access
a a
Cover, RH 1
1 21 600N90714-27 a Lower Web I
a
1
1 22 600N90714-29 Web Doubler
a
1
1 23 600N90714-31 Inboard Gusset
a a 1
1 24 600N90714-33 Outboard Gusset
a
1
1 25 600N9071 4-35 Shim 2
1 26 6001\390715-1 Seat Back Panel
a a
Support Assembly 1
1 27 HS4436F10N CamlocStud 1 3
Camloc Hardware 40847-10 Stud,
40G16-100 Grommet, 40S142-1-1AA
Retaining Ring, May Be Used As A
Substituted, Stud Lengths May Vary At
Installation, Use -9, -10, -11 Or -12
Grip Lengths
1 28 H54434-15 a a a Camloc Grommet 1 3
Camloc Hardware 40847-10 Stud,
40Glf~100 Grommet, 40S142-1-1AA
Grip Lengths
1 29 1 HS4424-1C Camloc Retainer
a a a
3
Camloc Hardware 40S47-10 Stud,
40G 16-100 Grommet, 40S142-1-1AA
Grip Lengths
Page 1006
Original CSP-103
Boeing Company
The CSP-103
Qty. Used
L Fig. Iteml I I per on ModellSerial No.
L No. Na. Part Number Description Assy. Code I From To
1 30 16001\19071 6-1 Lug 1 2
1 31 1600N9071 6-3 Bracket 1 4 B

Use On 6001\190710-503 Instl
See Also Fig 3
1 32 1369D290200-BSC a a Litter Assembly 1
See Fig 2 For BKDN
1 33 BLS3B08SL4 Pin I 6
Alternate MS17987-310
1 34 Not Used
1 35 BLDS3-09 Pin 1 2
1 36 1 MS17987-310 Pin 1 4
Alternate BLS3B09SL4
1 37 1 NAS1919C04S01W Rivet 8
1 38 NAS1 91 9C04S02W Rivet 135
1 39 NAS1S1 9C04S03W Rivet 11
1 40 1 NAS1919C04S04W Rivet 7
1 41 NAS1 73884-1 Rivet 1
1 42 NAS 173884-2 Rivet 54
1 43 NAS1 73884-3 Rivet 13
1 44 NAS1738B4-4 Rivet 12
1 45 NAS173885-3 Rivet 13
1 46 INAS1738CW4-2 Rivet 10
Alternate NAS1738M4-2 Installed Wet
1 47 INAS1739B5-2 Rivet 2
1 48 NAS1738B4-2 Rivet 6
1 49 NAS 1719C4L3W Rivet 4
1 50 MS20470AD4-2 Rivet 1
1 51 IMS20470AD4-4 Rivet 12
1 52 IMS2026AD3-4 Rivet 36
1 53 1 NAS1669-08L1 a a Blind Fastener I 6
1 54 INAS1664-08L2 a a Blind Fastener 1 9
1 55 1 NAS1669-08L4 a Blind Fastener 1 15
1 56 NAS1669-08L5 a a Blind Fastener 3
1 57 HS5603-5-5 Pin 1 12
1 58 IHS5583-5 Collar 12
1 59 IHS5603-6-3 Pin 1 2
1 60 HS5583-6 Collar 2
1 61 HS5608-1 88 Grommet 1
1 62 HS4435-2 Camloc Receptacle 3
1 63 IHS5788A6 Seal I AR
1 64 1 NAS1149FN816P Washer 1 14
1 65 120700 an Side 1 2
1 66 S1T13KU Strap 1 2
1 67 NAS1211810 Ring/Stud 2
1 68 NAS 1149F0732P Washer 1 3
1 69 1 MS21042L6 Nut 2
Page 1007
CSP-103 original
CSP-1OS The Boeing Company
Qty. Used
i. pig. Item per on ModellSerial No.
L No. No. Part Number Description Assy. Code Rom To
1 70 NAS6603-4 .Bolt 1 A
Use On 600N90710-501 Instl
1 70 NAS6603-4 Bolt 17 B
1 71 NAS6603-13 Bolt 2
1 72 MS21 042L3 Nut 3 A

Use On 6001\190710-501 Instl
1 72 MS21 042L3 Nut 19 B
Use On 6001\19071~-503 Instl
1 73 NAS11 49F0332P Washer 4 A
1 73 NAS1149F0332P Washer 36 B
1 74 91S2-8WO Camloc Stud 2
1 75 119-18 Camloc Receptacle 2
1 76 91S3-1 Camloc Retainer Ring 2
1 77 NASI 921 C04-03W Rivet 6
1 78 NAS7703-2 Screw ........._

22
1 79 NAS1149F031 6P Washer 25
1 80 MS21 076L3N Nutplate 21
1 81 MS20426AD4-5 Rivet 2
1 82 HS51 98-4004 Lanyard 2
1 83 HNS16-1124 4516 Material Sealing AR
Page 1008
Original CSP-103
19
28
~-29
14
29
19
28~ TOP VIEW
15
27
4 30
12
20 1\
10
11
10
11 o,
9\ 14
12
BOTTOMVIEW 21 20
f 27
30
13
25
17 16
18 22
23
O
u
24
6 26
60103-006
Figure 2. Litter Assembly Litter Kit
Page 1009
CSP-103 original
Qty. Used
L pip. Item per on Model! Serial No.
L No. No. Part Number Description Assy. Code I From To
2 1369D290200-BSC a a Litter Assy, Litter Kit REF 600N 000001-SUBS
See Fig 1 For NHA
2 1 3690290201 a a a Litter, Half, Assy, Litter Kit 2
2 2 369D290202 Tube 2
2 3 1369D290203 Web I 1
2 4 1369D290204 StiffeneT 1
2 5 369[)290205 a a a a
Hinge Plate 2
2 6 369H9261 0-7 Support B
2 7 13690290208 Skid 1 2
2 8 369D290206 Bushing 2
2 9 369[)290224 Ramp 2
2 10 1369D290225-3 Bracket 1
2 11 1369[)290225-4 Bracket 1
2 12 369D290207 Hinge 2
2 13 1369D290209 Handle 1 4
2 14 1369H92723-3 a a a Belt
Assy 4
Replaced By 369H92723-7
2 14 1369H92723-7 Belt
a a a
Assy 4
2 15 369H92723-5 a a Belt
Assy 4
Replaced By 369H92723-9
2 15 369H92723-9 BeltAssy 4
2 16 1 MS21083N4 NUt 8
2 17 MS20392-2C79 Pin a
2 18 MS24665-1 53 CotterPin 1 8
2 19 IMS20470AD4 Rivet I 10
2 20 IMS90353-06 Rivet, Blind, 100" 8
2 21 IMS20470AD6 Rivet 1 46
2 22 1 AN960C416 Washer 8
2 23 AN960-1 OL Washer 8
2 24 NAS1 304-25 Bolt 1 8
2 25 1 #896 Extrusion a a a Extrusion AR
2 26 369D290248 Washer 16
2 27 MS20470AD5 Rivet 1 2
2 28 369[39022993 Bracket 2
2 29 369D290229-5 Bracket 1 2
2 30 lH4629 Latch 2
Page 1010
Original CSP-103
The Peeing Company CSP-103
This Page Intentionally Left Blank
Page 1011
CSP-103 Original
11(2)/ !4(2)
(4 PLS)
5(2)
14 (2)
15 6 (2)
(6 PLS) 8
3(2)
10 (2)
WITH STANDARD BENCH SEAT
WIRI OPTIONAL BUSINESS SEATS

600N90716-3(REF)
22~ 9
17,
26 23
(2) 25
23
24
25(5 PLS)
t 21 (2 PLS)
(4 PLS) 16
25 (2)
27
16----~ (2PLS)
(2 PLS)
00
n M n n
6p103-007
Figure 3. Support Assemblies Mid Support AssylAft Support Assy
Page 1012
original CSP-103
Qty. Used
L Fig. Item per I on ModellSerialNo.
L No. No. I Part Number Description Assy. Code From To
3 1 600N90711-501 Mid Support Assy, Litter Kit 1

See Fig 1 For NHA
3 2 600N90711-3 Beam 1
3 3 600N90711-5 Rod 1 2
3 4 600N90711-7 Rod 1
3 5 600N90711-13 ..Tee 4
3 6 1600N90711-15 Rod Assembly 2
3 7 MS20470AP~16 Rivet 2
3 8 600N90711-11 Rod 1
3 9 1600N90711-9 Clevis 1
3 10 1600N90711-17 Clevis 1 2
3 11 BLS3B08SL4 Pin 4
3 12 NAS6603-4 Bolt 1 4
3 13 NAS6603-14 Bolt 1 6
3 14 NAS 1149F0332P Washer 20
3 15 MS21042L3 Nut 10
3 16 Msl 7987-310 Pin REF
3 17 600N90712-501 Support Assy, Aft End 1

See Fig 1 For NHA
3 18 600N90712-3 Rod 1 2
3 19 600N9071 26 Plate I 1
3 20 600N9071 2-7 Beam 1
3 21 600N9071 2-9 Collar 2
3 22 600N90712-11 Latch 1
3 23 1 MS21042L3 Nut 9
3 24 NAS514P1032-8 Screw 1 5
3 25 NAS 1149F0332P Washer 17
3 26 NAS6203-15 Bolt 1 4
3 27 NAS6603-13 Bolt 1 2
Page 1013/(1014 blank)

CSP-103 Original

2294

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ATP

INDEX COPYRIGHT 2002

COPYRIGHT IS NOT CLAIMED AS TO ANY PART OF AN ORIGINAL WORK

"ATP" is a registered trademark of Aircraft Technical Publishers. All original

ALL RIGHTS RESERVED. NO PART OF THIS PUBLICATION MAY BE

Brisbane, CA 94005 (800)227-4610

ATP Grid Index to Manufacturers Publications:

Optional Equipment Supplements

CSP-003 Engine Auto Reignition (P/N 369H90118-513,-515)

Illustrated Parts List

CSP-008 Attitude Gyro Indicator (P/N 369H90038-501)

Illustrated Parts List

04/19/2002 Copyright Aircraft Technical Publishers Page 1 of 9

CSP-009 Direction Gyro Indicator (P/N 369H90039-501,-503)

Illustrated Parts List

CSP-010 IVSI (Instant Vert Speed Ind) (P/N 369H90044,-503)

Illustrated Parts List

CSP-012 Transpondr Instl (KT-76)(369H90073,-501,-503,-501)

Illustrated Parts List

CSP-015 ADF (KR85) (369H90067,-501,-51,-61)

04/19/2002 Copyright Aircraft Technical Publishers Page 2 of 9

Record of Temporary Revisions

Illustrated Parts List

CSP-016 Nav/Comm Transcvr Instl (369H90071,-503,-507,-509)

Illustrated Parts List

CSP-017 Integratd Intrphone (ICS) Instl (P/N 369H90068-11)

Illustrated Parts List

CSP-019 Auto Direction Finder (KR 86) (P/N 369H90056.-501)

04/19/2002 Copyright Aircraft Technical Publishers Page 3 of 9

Illustrated Parts List

CSP-020 Radio Instl (ASB-125/60) (369H90144-501,-503,-505)

Illustrated Parts List

CSP-023 Cyclic Stik Grip Kit Instl (P/N 369H90129-31.-505)

Illustrated Parts List

CSP-026 Litter Instl (P/N 369H9011-511,-517,-519,-521)

Illustrated Parts List

04/19/2002 Copyright Aircraft Technical Publishers Page 4 of 9

AFT Stanchion Assembly

CSP-029 Passenger/Cargo Hoist Sys (P/N 369H90070-521,-522)

Illustrated Parts List

CSP-032 Searchlight Installation (P/N 369H90142)

Illustrated Parts List

CSP-033 Public Address Siren Sys Instl (P/N 369H90143)

04/19/2002 Copyright Aircraft Technical Publishers Page 5 of 9

Illustrated Parts List

CSP-036 Seating Belts for Four (P/N 369H90035-501,-503)

Illustrated Parts List

CSP-071 Litter Installation (P/N 3690290170)

Illustrated Parts List

04/19/2002 Copyright Aircraft Technical Publishers Page 6 of 9

CSP-084 TDR-950 Transponder System

Illustrated Parts List

CSP-087 Float Lamp Assembly (P/N 3690292032)

Illustrated Parts List

CSP-089 Dual Starting Kit (P/N M30306)

Illustrated Parts List

CSP-094 Engine Air Inlet Diverter Kit (P/N See TP)

04/19/2002 Copyright Aircraft Technical Publishers Page 7 of 9

Illustrated Parts List

CSP-100 250-C20R/2 Eng Conversion Instl Kit (P/N See TP)

Illustrated Parts List

CSP-102 Upgraded Trans Conversion Model 3690,E,FF,500N HEL

Illustrated Parts List

Upgraded Main Rotor Driveline Modification Kit

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